post #1 of Old 01-01-2012, 06:10 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
2.5 to 5.3 4l60E Swap / Build Thread

I picked up a 97 2.5L wrangler with 108K on it and a ton of work already done to it. It was pretty close to what I would have built myself so I figured let someone else dump $10K plus plenty of work.

This is what it had when I bought it:

5.5 Rubicon long arm lift with 3 link wishbone rear
Rubicon D44's front and rear with ARB front and Rubicon locker rear with 5.13's and alloy shafts.
37" Toyo MTR's
2" body lift
Warn 9000I
Super short SYE with Tom woods rear shaft
Custom rear bumper with tire carrier

Changes I've made so far:

Remove body lift
Trade 37" toyos for 35" MTR's

Planned mods

Front tube fenders, sliders, rear corner guards with tubes
Anti-rocks front and rear
3" Currie / Savy springs (already purchased)
Bilstein shocks
Limiting straps
New seats
Front bumper

And the biggie....


5.3 with 4l60E

clintrivera is offline  
post #2 of Old 01-01-2012, 06:19 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
I picked up the 5.3 a few days ago from a 2001 Silverado with 70K on the clock. It came with the ECU, full accessories (minus the starter and A/C) and the harness for $700. I also scored on a low millage 4l60E from a 2000 Tahoe with 60K on it for $400 a few weeks ago.

Here's what I'm starting with.






I started at 9am and by 10:30 I had this.



Had the engine, trans, and transfer case pulled by 12:30. Wranglers are super easy to pull engines since you can pull the entire front clip!

Before I pulled everything out I made a little reference mark to show where the transfer case was positioned forward and aft.



I started to weed through the factor wiring harness to eliminated everything I didn't need anymore. I'm keeping the factory ECU to run the guages.





I have ordered a bunch of parts and have quite a few left. I'm hoping to keep the budget somewhat in control yet do everything "right".
clintrivera is offline  
post #3 of Old 01-01-2012, 06:26 PM
jon1371usmc
Registered User
2004 LJ Wrangler 
 
Join Date: May 2009
Location: Nashville
Posts: 305
Looks like an awesome build.
jon1371usmc is offline  
post #4 of Old 01-01-2012, 09:46 PM
Ryanw10
Registered User
1997 TJ Wrangler 
 
Join Date: Nov 2011
Location: West Olive
Posts: 351
5.3L in a tj...funnest thing to drive. Im running 30" tires right now until I can afford some new tires and my 0-60 is about 5 seconds
Ryanw10 is offline  
post #5 of Old 01-01-2012, 10:04 PM
sduncan
Registered User
 
sduncan's Avatar
1998 TJ Wrangler 
 
Join Date: Oct 2004
Location: Bakersfield
Posts: 1,604
Looks like you are well on your way. Good luck and post plenty of pics.
For a GM swap I think that Advanced Adapters and Novak will be your new best friends...
sduncan is offline  
post #6 of Old 01-02-2012, 06:37 PM
Barrows
Registered User
2003 TJ Wrangler 
 
Join Date: Nov 2008
Location: Union
Posts: 280
Can't wait to see more.
Barrows is offline  
post #7 of Old 01-07-2012, 06:25 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
Had a little setback. The wiring harness that came with the engine was a bit hacked and missing a few connectors. Rather than rummage through a junkyard or order new connectors I ordered up a new harness.

Started tearing the motor down for a little cleanup and inspection.

This is what I started with.



Pulled the intake off. Yes, there are two cigarette butts and an earplug sitting there.



Motor looked pretty good except for one broken exhaust manifold bolt and a somewhat suspect valve. The spark plug had some deposits on it. I'm going to run a leak down test on it and see if it's OK.



After pressure washing and some super clean. Still going to paint the balancer and power steering pump pulleys.



I received Novak's "black box" the other day (for the tach signal and stock gauge) so I wired it up and shrunk wrapped all the other loose wires.



I also installed my auto brake pedal.



And cut out the old mounts and tacked the new Novak mounts in.





I'm hoping the valve is OK. If not I found rebuild heads for around $180 so it's not super serious.
clintrivera is offline  
post #8 of Old 01-08-2012, 12:17 PM
Ryanw10
Registered User
1997 TJ Wrangler 
 
Join Date: Nov 2011
Location: West Olive
Posts: 351
Will that novak box allow you to run the stock tachometer? I have a 5.3 in my tj and I kept the jeep pcm so I could run the gauges but I was planning on just getting an aftermarket tach. I would much rather prefer to use the stock tach
Ryanw10 is offline  
post #9 of Old 01-08-2012, 06:54 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
Yes it will. I wanted to keep my stock gauges and $150 for a black box was a lot cheaper, easier, and IMHO looks better. Hook up a few wires, and you are good to go.
clintrivera is offline  
post #10 of Old 01-08-2012, 08:19 PM
Ryanw10
Registered User
1997 TJ Wrangler 
 
Join Date: Nov 2011
Location: West Olive
Posts: 351
Thats pretty cool I might have to consider that.
Ryanw10 is offline  
post #11 of Old 01-08-2012, 08:27 PM
chmo
Registered User
2006 TJ Wrangler 
 
Join Date: Nov 2009
Location: Abu Dhabi
Posts: 1,292
The Tach emulator Box is available in three different versions from Novak for XJs/TJs plus one more version for JKs to match the different bus protocols!

"The more I know, the more I realize how much I don't know"
my LS1 swap build thread
THE cheap progressive bump stop solution
chmo is offline  
post #12 of Old 01-14-2012, 08:43 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
Made some more progress today and dropped the engine in. I'm impressed with how well the engine fits. Almost like it was intended to be there. The Novak mounts made everything a breeze.





I used 2010 Camaro LS3 exhaust manifolds and it looks like they will work out great!



Plenty of clearance around the steering shaft too.



Also had time to swap out the 5.5" RE springs for some 3" Savy / Currie springs. The wire diameter of the Savy springs are thinner, so the ride should be a bit better.



Gonna drop the gas tank and work on my hybrid np231J /C transfer case.
clintrivera is offline  
post #13 of Old 01-14-2012, 11:04 PM
Tyler99TJ
Registered User
1997 TJ Wrangler 
 
Join Date: Jun 2008
Location: Centerville
Posts: 432
Are you keeping the transfer case in the same location so that you keep the same drive shaft length? What do the new motor mounts key off of for alingment?

Looking to make this swap next winter and will follow your build.
Tyler99TJ is offline  
post #14 of Old 01-14-2012, 11:11 PM Thread Starter
clintrivera
Registered User
1998 TJ Wrangler 
 
Join Date: Sep 2005
Location: Pacific
Posts: 2,781
I haven't gotten the adapter for the transfer case yet, but I think it's going to push the case about 1.5"-2" back. This is for a swap with a 4 banger and AX5 transmission, so keep that in mind. I'm also not using the usual "swap the mainshaft out of the 4l60E" adapter so it's going to end up an inch or so longer.

For the mounts you measure back from a hole in the frame and burn the mounts in.
clintrivera is offline  
post #15 of Old 01-14-2012, 11:18 PM
MO2500
Registered User
1997 TJ Wrangler 
 
Join Date: Mar 2009
Location: Denver
Posts: 7,170
I'll be watching. Pretty much the same swap I would like to do at some point down the road. I already have the truck to pull the 5.3 and trans from. Keep up the great work

ODonnell Motorsports
Build Thread
Instagram: @omsmike
MO2500 is online now  
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
90 4.2 to 95xj 4.0 Swap Build Thread yjcrawlr YJ Wrangler Technical Forum 282 12-10-2011 07:30 AM
My 8.8 build/swap thread SeanWilliams YJ Wrangler Technical Forum 54 11-16-2011 07:17 PM
8.8 Swap Into TJ Build Thread GreenJip TJ Wrangler Technical Forum 154 04-14-2011 04:30 PM
4.0 Swap Walkthrough, Build Thread all in One !!!! cevans87 YJ Wrangler Technical Forum 10 03-09-2010 11:20 AM
D35 swap to Ford 8.8 build thread. northjeep YJ Wrangler Technical Forum 9 02-01-2007 08:08 PM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome