Tips re: relocating and welding motor mount perches? -
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Unread 03-20-2013, 08:38 AM   #1
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1995 YJ Wrangler 
Join Date: Apr 2002
Location: NYC
Posts: 517
Tips re: relocating and welding motor mount perches?

G'morning all,

So I'm making great headway with my 2.5L to 4.0L swap in my '95 YJ. I'm finally ready to set the new motor in the engine bay. As you may know, installing the 4.0 requires relocating the motor mount perches (moving them towards the front).

I have carefully and cleanly removed the existing perches, and prepped them up real nice so that they fit cleanly over the frame rail. All rust & paint has been removed, and I'm ready to weld with my MIG.

I have the engine hanging from an engine lift with a motor leveler, and have it as level as possible.

I plan to move the motor/trans/xfer case into position and align front/rear using the transmission mount (cross member) bolt holes. I also was planning to measure from the center of the crankshaft to each of the frame rails to center the motor left/right.

Any suggestions regarding how to make this easier and to get it right on the first attempt? Once the motor is nearly in position, do I just lower it until the perches sit firmly on the frame rails, and tack it into position?

I really only want to do this once and don't want to spend all weekend on it, so any tips are appreciated. Cheers.

'95 YJ 123bhp 4-banger powerhouse.
UPDATE: 2.5L ENGINE RETIRED; she was still running strong at 212,000mi.
4.0 swap in progress.
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Unread 03-20-2013, 09:46 AM   #2
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2005 TJ Wrangler 
Join Date: May 2009
Location: Eaton Rapids, Michigan
Posts: 6,533
I did it similarly for my 2.5 --> 5.9 swap. My 5.9 mounts were different, but the process is about the same. I carefully cut the old mounts off (didn't reuse them, but they could be reused), then fixed any nicks on the frame from cutting. I positioned the new mounts and held them in tightly with clamps, moved the engine into place and finished aligning the mounts. I put a tack on on each corner of the mount, then re-checked the alignment. If there was a change needed, I would have done it here, but there wasn't so I burned them in.

It sounds simple, but I pulled the engine out and put it back in about 50 times before I burned them in.
"Ugly Betty" Build - 97 TJ 5.9 Magnum / 46RE Swap

Originally Posted by ashland82391 View Post
We're men! We don't need no stinkin directions!
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