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Thread: 2.5L to 4.0L Conversion

  1. #1
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    2.5L to 4.0L Conversion

    Project 98SE-02APX

    My Jeep
    -1998 SE
    -2.5L/AX5
    -166xxx


    New Plant
    -2002 Apex
    -4.0L/NV3550
    -110xxx


    Profile
    Well, I decided to undertake the swap because highway driving was doable but simply strenuous on the small 4. The AX5 started chiming in saying it was time...

    I bought the drivetrain complete with tcase, shafts, PCM and d/t harness, CA intake, and exhaust from another member on here.

    I started in early Sept/09 with the intent to complete it before the winter would show - didn't happen. I didn't quite expect, although in hindsight it was so obvious, to run into some of the issues I did.

    With that said, the new engine is strapped in the frame - now is just electrical. I'll be writing up a decently detailed of everything I did shortly.

    Special thanks to:
    My dad(for letting me take up the garage)
    Czarny
    Ralph
    Ben
    Justin
    Noltz
    RavenCrox

    And anyone who I didn't mention that contributed and helped in some way.

    Also check out JWJeeps. They have absolutely everything when it comes to used parts and very good prices. They're in Cali, but man, if you need it they have it. From MB to JK.
    Last edited by MikNov; 01-25-2010 at 03:30 PM.
    -Marco
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    Cool!

    I'm looking forward to reading this... Sweet looking Jeep BTW!

    If I was a Jeep, they'd have parted me out a LONG time ago.

    I'm a proud member of SOXJA ask me why!

    Krawlerz team member too!

    OF4WD Member # 5027

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    now would be the time for mounting and electric fan and positioning the engine as far foward as possiable and motor mount lift

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    I just finished the same on a yj, have fun lol
    WARNING! I am about to do something really fawking STUPID!!!!!!
    ᄅ# pɐǝɹʇǝɹ
    93 YJ- RIP- parted out like I should be

  5. #5
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    I'll start off by listing what I needed/what I got to make this happen (I'll list the obvious stuff too)

    Parts Needed For Swap
    -02 4.0L
    -NV3550 Transmission
    -NP231 Transfer case from 4.0 - 2.5L won't work because of different spline count
    -4.0L drive shafts - rear is shorter/front is longer than 2.5L DS's
    -4.0L exhaust and catalytic
    -Frame mounts left & right (dealer only part)
    -Engine mounts (Brown Dog Offroad)
    -MML (Brown Dog Offroad)
    -Engine Control Module (ECM)
    -Motor/trans/tcase harness
    -2002 Body harness complete
    -2002 gauge cluster
    -Power steering pressure line
    -Power steering fluid container
    -Power steering feed line

    Cannibalized Parts From 1998
    -Starter
    -Steering brace mount - with mods - has to be extended
    -Radiator
    -Radiator hoses


    Some Notes
    -2003 gauge cluster doesn't work because of different ports
    -2003 jeep transmission skid sits 1" further back than pre-2003

    *I'll be updating this post as I go with part numbers and things I forgot.
    **As it stands, I'm not working on it now because I don't have heat in the garage - doesn't help its made out of cinder block and the floor is cemented - its a cave
    Last edited by MikNov; 01-25-2010 at 03:36 PM.

  6. #6
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    Last time she stood as a 2.5L


    Engine out


    Engine Gone


    Mopar frame engine mounts


    Brown Dog 1" MML


    Brown Dog Engine mounts


    Engine In


    Positioned, tacked, and welded frame mounts

    Last edited by MikNov; 12-22-2009 at 02:55 PM.

  7. #7
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    I opted on making my own frame engine mounts supports instead of buying overpriced metal from mopar




    I reused the stock steering shaft brace mount


    The steering shaft brace has about 5" of play - just needed some motivation to slide it back - it has to sit in behind the driver frame mount

    Steering shaft brace mount welded and primed in
    Last edited by MikNov; 01-25-2010 at 03:38 PM.

  8. #8
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    These may come to use for someone. They helped me as a general reference, because I already shaved off my passenger mount from 2.5L by the time I came across them. They're from a Jeep engineer that were made for a brother called Ralph who helped in every way he could.

    The diagrams are comparing from the 4.0L mount should sit compared to that of where the passenger 2.5L sits. I have bigger images should you need them - photobucket sized them down to 800x600.













    Here is also a diagram on what has to be replaced when doing odd year swaps - practical? nope....but I'm committed.


    Quote Originally Posted by JPhoenix View Post
    Cool!

    I'm looking forward to reading this... Sweet looking Jeep BTW!

    Thanks!

    Quote Originally Posted by BadCompany View Post
    now would be the time for mounting and electric fan and positioning the engine as far foward as possiable and motor mount lift
    One day ill do the electric fan - not today unfortunately - i'm waaaay over budget with it as stands. Yea, the MMLs were a must since it was out already.

    Quote Originally Posted by thing1 View Post
    I just finished the same on a yj, have fun lol
    Yea, the electrical is a pain in thy behind. But hey, I always wondered what and where everything was setup - guess I got what I thought about.
    Last edited by MikNov; 01-25-2010 at 03:41 PM.

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    Looks good Marco, but I'm curious... For all the work, why not a 5.2L or a 5.9L? I'm sure the price of the swap would have been comparable? I ask because I also have the 4 pooper and am considering a future swap.

  10. #10
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    Quote Originally Posted by the_art_of_design View Post
    Looks good Marco, but I'm curious... For all the work, why not a 5.2L or a 5.9L? I'm sure the price of the swap would have been comparable? I ask because I also have the 4 pooper and am considering a future swap.
    I've considered that point. I'm prolly close to 2 grand away from doing a V8 swap money wise.

    Truth be told, when I started off I didn't budget for swapping out the body harness and cluster which cost me close to 750 canadian to get in my hands after shipping, border duty tax (and fine).

    I got the drivetrain plus other stuff for a good deal from Czarny. Basically a donor 4.0L jeep for nearly 80% of all major components. Plus timing, schedule and when I needed to get it done by also influenced why I went with the 4.0L.

    I wouldn't go with a v8 either - too much for my preference.
    Last edited by MikNov; 12-22-2009 at 04:21 PM.

  11. #11
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    Exact reason I purchased a complete other truck that had been written off. Get all the parts in one shot without having to worry about anything missing or waiting for parts. It's quite the bitch but worth it in the end. The only parts had to order were the motor mounts at the frame and they were available next day from Mopar.

    Adrian
    Poster does not represent or warrant the the information accessible via this post is accurate or complete. Except as specifically stated on this post, neither rbjeepthing nor any of his affiliates, will be liable for damages arising out of or in connection with the use of this post.

  12. #12
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    Totally.

    Can hardly wait to drive up a low gradient road!

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    You're certainly doing it the right way at least.
    ....-Noltz
    '91 Frankenheep Edition. 4.0, 4" BDS, Richmond 8.8, 35" KM2's, Titan 12k, ... gone.
    '95 4Runner SR5. Air-Lift bags, OBA & 8K Winch, DD... gone.

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    Here's as she stands currently. I got my cluster and the other half of my body harness that runs along the firewall which connects the fuse box in the glove box and the PDC.





    As a note - 4.0L exhaust couplers to the 2.5L couplers. They're different.

    4.0L coupler.


    This is a pic from the coupler connecting the downpipe to the manifold. You can also see that all the 2.5L uses is a clamp to the cat. Unlike the 4.0 which uses bolts.


    I believe its also bigger in diameter.
    Last edited by MikNov; 01-25-2010 at 03:43 PM.

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    What'd you get fined for?

  16. #16
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    Quote Originally Posted by NINE-T-1-RENEGADE View Post
    What'd you get fined for?


    For being the sexiest man alive



    I didn't have a receipt (later found on the box). Not being complete in producing what the value of the goods are. They found out by calling JW, and getting them to fax the receipt. Didn't think it'd be such a big deal considering its used junk by comparison to anything else that is bought across the border.....so duty plus a 30 dollar fine.

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    Quote Originally Posted by MikNov View Post
    For being the sexiest man alive



    I didn't have a receipt (later found on the box). Not being complete in producing what the value of the goods are. They found out by calling JW, and getting them to fax the receipt. Didn't think it'd be such a big deal considering its used junk by comparison to anything else that is bought across the border.....so duty plus a 30 dollar fine.
    And you've made "The List"

  18. #18
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    Ah yes.... The list. I am very (un)fortunate to be on this list.. I was in Ogdensburg yesterday to pick up these photo albums.. Total was around $100. I had to go pay taxes... Once on the list, they nail you for everything.... Buddy was in Messena on Saturday, brought back almost $300, let him right through. He's not on the list...

    Stay off the LIST!!!!

    BTW, nice stuff Marco.. Keeping an eye on this as i am certain it will be a future change for me too!
    RIP OD, YOU'LL BE MISSED.... BUT that's OK 'cuz you've been REPLACED !!!

  19. #19
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    Fawwk. Didn't think about that. Blows. Ah well. List it is. Guess there won't be a cigarette smuggling future for me...

    Thanks countryboy, if you have any questions - feel free. Goes for anyone else as well.

  20. #20
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    Update: Well, everything is at a stand down. My fingers are no good for beans in the cold, 5 minutes and I lose all sensation...no good for wiring in the cold. Until I get a gas line installed into the garage to get my heater going, she's gonna have to wait. Probably will be leaving for an 8 week course come the 14th as well - maybe.

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