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Unread 03-27-2013, 03:11 AM   #1
theGiantPanda
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Tailcrusher.. 2.5 to 5.3 Swap

Figured I'd start a new thread to cover this one and move the discussion off of the other swap threads, especially seeing that the 5.7 HEMI TJ is almost done!

and... Brians 2.5 to 4.0L heep to jeep swap build project is almost done as well!

This is will be my/our first LS swap. I have set a budget and we will be sticking to it.

This jeep will named TAILCRUSHER because I found out when we got the motor out of the truck at home, when it was first set in the truck, it was set down right at the bottom edge of my tailgate... YESSIR crushed/dented it pretty good. didn't even realize it till I dropped the tailgate to clean it at the car wash and it hit the under bed running lights..:rantscrea m: guess I might have been more mad if the tailgate hadn't been crushed on the painted side before by me and an "unlocked' trailer coupler.

The goal is to stay well under 10K with the complete build [motor swap lift tires repairs paint etc]. I am picking up a 2000 TJ this afternoon, 2.5L 5 speed, black with tan interior and tan hardtop. The jeep was smacked in the front drivers fender, but it didn't touch the tub! The guy is including 2 new fenders and a new hood in the deal.

The other day I picked up a low mileage LM7/5.3 Gm LS Series motor, ecu, 4L60E trans and other random parts for a local yard. currently on the search for a gm 231c case to do the 231c/231j masterpiece.

VSS
I will use both the jeep vss and the gm vss to make all the computers happy. The gm vss will be modded into the trans/tcase adapter. jeep vss will remain in the jeep tail cone. I will be moving into the mega short SYE for this one. I wish I would have went that way on the HEMI swap, could have used a few extra inches..

FUEL
I am going to use the stock 2000 fuel pump/tank assembly. I will be modding the stock regulator, getting a fitting from Novak, or possibly having my buddy CNC me a new fitting all together. The 5.3 we have for this swap is regulated at the RAIL and requires a return line to tank. Fuel lines will be upgraded to 3/8 aluminum and utilizing a bulkhead fitting to create the return port.

SHIFTER
after reading about some annoying issues trying to set up the lokar shifter in threads by some forum friends, I re-enforced my plan to keep and utilize the stock TJ auto shifter set up. It can be done with a little trickery and the right parts.

COOLING
Aftermarket Aluminum 2 core radiator, stock GM clutch fan.

EXHAUST
I'll be utilizing 2010 Camaro exhaust manifolds at the motor. The rest will be fabbed by the exhaust shop. I will be running the upper o2 sensors, no cats and flowmaster series muffler.

TRANSFER CASE
found a GM 241C that im going to pick up. I am going to use the front half of the case and the 241c input shaft, planetary gear set etc with the back half of the 231J and a super short SYE kit. the 241c should have a 6 gear planetary vs the 231j and a 1.25" wide chain set. for the front driveshaft to connect to the 241, will just be a matter of a few pieces from the local driveshaft shop. possibly just a conversion U Joint or new yoke. the 241/231 new process transfer cases are the same size, just chevy had new process rotate their mounting bolt pattern. the 241 is considered a medium duty transfer case, due to the larger internals than the light duty 231 series. at least that's what i read. and everything on the internet is true... bon jour'

WIRING/GAUGES
I'll be doing the engine harness myself. I plan on using Brendan over at LT1swaps for the computer programing or wayne off the pirate board. I will be running both the jeep ecu and the gm ecu so I can retain the stock cluster. The tach will be resolved by novak or redline... plans are to add a second datalink port for the LS under the dash.

LIFT
ZONE 4" Suspension and 1.25" body lift. I'll be fabricating adjustable uppers this time around as well.

WHEELS/TIRES
Retain stock, unless budget allows for some kind of aftermarket. Wheel spacers and Federal 35x12.50R15s.




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Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
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Unread 03-27-2013, 12:16 PM   #2
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We re going to pick the jeep up in the next hour or so. Last night I emailed a local jeeper who has a jeep parts yard. Looks like about $250 for all the miscellaneous pieces I need to get the front back to stock and all the auto swap pieces too. Ill post some shots when we get back. My buddy is already asking if he can by the jeep from me... he knows I would rather have one with less work to get it back to good... so i can concentrate more on the LS swap than 'rebuilding' he's trying hard to sell me on it.
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Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-27-2013, 01:36 PM   #3
clintrivera
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Looking forward to seeing this one.
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Project Indecision: A Jeep Addicts 06 LJ

http://www.jeepforum.com/forum/f22/p...ed-lj-1741722/
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Unread 03-27-2013, 03:36 PM   #4
ChiliPep99
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Subscribed! Good luck and post lots of pics for the visual learners such as myself. Do you plan on giving a parts list at the end?

Thanks!
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Unread 03-27-2013, 07:06 PM   #5
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Ok we picked up the jeep this afternoon. We where racing the clock for a minute and I forgot to take pics.. WTF dumb@ss. Ill swing by my brothers and snap a few.

Ill fill this thread with tons of pics! Ill post links to photo bucket when I get a new library set up for it.
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Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-27-2013, 11:54 PM   #6
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ok so its was too late when i left the garage to stop at my brothers. truth is, i think eddie is going to go get some cash to get the jeep from me LOL. he called it an early night in the garage so he could go 'talk' to his girl about it.

needless to say idle time is not a good thing in the garage...


well i figured id get to messing with the fuel system tank plumbing seeing that we had an extra 97-04 fuel pump assembly floating around. I want to use the factory pump and loose the regulator and I don't want to buy a 180 kit to do it. so i have come up with 2 solutions. option 1 involves some an fittings, washers and RTV. option 2 involves my buddy and his new cnc lathe! both solutions should result in the ability to retain the stock fuel pump 'setup' meaning still have the 'tension spring and riser tube' in place and functioning. if neither pan out the way i want, then the 'fall back' is high pressure line between my fitting and the fuel pump.

I took the stock pump apart and broke it down into its components. Made sure I understood how it all 'worked.' the fuel pump connects to the steel riser tube and is sealed by a rubber grommet. the tube also acts as a tensioner, keeping the lower basket 'pushed' against the bottom of the tank. the upper portion of the riser tube slides onto the plastic shaft that is sealed to the 'regulator port' with an O ring. the shaft allows the riser to 'adjust to the depth of the tank.' the shaft is about 3/8" in diameter

I started to solve this project through option 1. option 1 will require about a few AN fittings to make. now the stock pressure regulator dumps fuel from ports around the shaft, which pours cold fuel on the fuel pump to keep it cool. to allow for this cooling feature. the basket holds fuel around the pump and dumps the excess once it is full, over the top edge into the tank. i have [2] solutions A-bulkhead fitting through plastic off to the side with line dropped back into 'basket' option B drop line directly down into the tank and drill a few holes in the basket to allow fuel to flow through and cool the pump as well. maybe ill drop the line down and plumb it into the side of the basket and replicate stock. either way i am trying to avoid aerating the fuel.


heres the regulator, tension spring and riser tube


heres the stock upper assembly. the riser slides on the plastic shaft. the unused fuel pours back into the tank at the area of the top of the shaft where it changes to about 1" in diameter.


here you can see where the fuel pour out around the intake shaft


we are cutting the stock intake shaft off the housing


now something i can work with




i grabbed a random AN fitting to see what 'I had' to work with. looks promising to me. obviously im not going to use an 10-AN fitting LOL
__________________
Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-28-2013, 09:50 AM   #7
clintrivera
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Just make sure you don't loose the rubber one way valve on the bottom of the fuel pump "can". Bad things will happen when you get low on fuel.
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Project Indecision: A Jeep Addicts 06 LJ

http://www.jeepforum.com/forum/f22/p...ed-lj-1741722/
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Unread 03-28-2013, 10:14 AM   #8
Jeepsr4me
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Will the transfer case just hook to a 2x4 trans or will you have to swap out the main shaft?
This is my next project, so keeping eyes on ya for pointers.
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Unread 03-28-2013, 05:20 PM   #9
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The jeep t case won't mate to the chevy correctly. The bolt patten is rotated about 90' from the Chevy bolt pattern on the 4wd adapter on the back of the trans. You can use an AA or Novak adapter kit but those run high $$$. I found an adapter on eBay that may work too. ***** I'm gonna talk to my Cnc guy ... Oh it's on now. More to follow when I get home and off this phone!!!
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Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-28-2013, 10:06 PM   #10
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hummmmm waiting on pics to load....
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Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-28-2013, 11:03 PM   #11
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clint.. right on, I saw that little guy down there when I took it apart. i was actually thinking about changing the flow ports on the basket when I start messing with the new fittings.

heres the potential new candidate for the LS swap.. aka my practice jeep..lol. not sure eddies gonna get it or not just yet, so im moving forward with parts acquisition and development.





the bad


the inside

__________________
Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-29-2013, 12:38 AM   #12
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went out to the jeep parts yard today and got all the stuff to got to an auto, replacement flare, hood latches, grille support bars, pass floor patch panel, good stock gas tank skid, 40 fender mounting bolts, marker light housings, extended bump stops for the blue TJ and some other parts for brians jeep.
__________________
Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-30-2013, 12:11 AM   #13
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today my buddy went to see if they could get a loan to get the jeep from me. ill know on Monday whether this jeep will be getting an LS now or next fall for eddie LOL... back to looking for new canidates if he indeed buys it off me...
__________________
Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
My new DD Build, lift, 4.0 motor swap, done in 6 days?....http://www.jeepforum.com/forum/f22/6.../#post15716292

the new shop... http://redrockwiring.com/ conversion, parts and wiring systems
shop email.... info@redrockindustries.net
LIKE US on facebook..... https://www.facebook.com/redrockindustriesinc adding more daily
redrockindustries.net
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Unread 03-31-2013, 12:31 AM   #14
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today was a play day
eddies Cherokee we just finished fixing and 'adding' to



found my next truck...


little playing... click on to play
__________________
Quote:
Originally Posted by CCJ View Post
Jesus. This is what heaven on 4 wheels looks like.
Quote:
Originally Posted by Deacon View Post
Hospital? What, are you suffering from Overextended Jeepaphelia or something? :)
I've never been poor, only broke. Poor is a state of mind. Broke is a condition brought on by Jeep ownership and a heavy right foot.

2006 Unlimited Redicon Panda Edition
RRI Long Arm...14" Fox CO's Front and Rear...D60 KP Front and D60 FF Rear... 5.38s spooled...40" Maxxis Trepadors...
6.1 HEMI...Atlas 5.1

5.7 HEMI 400 hp TJ Build http://www.jeepforum.com/forum/f9/ye...17/?highlight=
6.1 HEMI Ultimate LJ Rubicon Build http://www.jeepforum.com/forum/f9/6-...ayhem-1013800/
2.5 to 4.0L swap and build up http://www.jeepforum.com/forum/f9/he.../#post14946167
4.0 to 2008 5.3L GM LS in the Taco'd TJ [frame off build].....http://www.jeepforum.com/forum/f9/5-...28/?highlight=
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Unread 03-31-2013, 06:08 AM   #15
rda616
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1998 TJ Wrangler 
 
Join Date: Nov 2008
Location: Allegan, Michigan
Posts: 3,008
I didn't think the 241 and 231 cases were compatible. I have seen lots of 231c hd, 231j combinations, but can't recall anyone fitting a 241 to a 231.
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