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XDR's 5.3l TJ Build

30K views 92 replies 15 participants last post by  delsolcharlie 
#1 · (Edited)
Going to compile a complete build list here on the first post followed up by photos.

A little history of the Jeep... I purchased the Jeep in December with intentions on doing the v8 swap. With that in mind I found a 4 cylinder that had an exhaust leak for $5000, which eventually was talked down to $4400. The next cheapest TJ in a 6 hr radius was around $6000. The Jeep is a 1997 TJ and had a non-ac 4 cylinder with the AX5 transmission. 148k on the odometer and drove it the 2.5 hrs back home with no issues. Rolled it into my garage and got to work, the front rotors were toast so swapped them out real quick then got to work on removing the front fenders and grille. Pulled the engine/transmission/transfer case out in one shot. The skid plate had 2 bad nutserts so had to cut bolts off, will post some info on nutsert replacement later. To this point the passenger front brake line had been replaced with a homemade line, which I'll be replacing with a new one.

As of current I have cut old 4 cylinder motor mounts off and getting it ready for the new motor mounts.

Current Build List:

2000 5.3l with 115k ($1800)
NV3550 (Rebuilt) ($900)
Advance Adapters Bellhousing 712591V ($285)
Toyota Land Cruiser Slave Cylinder ($65)
Machined NV3550 Front Bearing Seal for clutch ($20)
Transfer Case Parts -
HD Super Short SYE w/1310 CV Yoke16-1201-1945 ($300)
Partial Master Rebuild Kit For transfer case ($200)
Input Gear-NVG 23 spline-long, late tooth 1995 and newer ($150)
Wide chain & sprocket kit ($225)
Novak Motor Mounts ($196)
Novak Fuel Kit ($268)
Fuel Rail w/ no return ($45)


Still to be purchased:


29-2321 : NP231 Transfer Case Heavy Duty Planetary $185.00
716179V : Modified GM Release Arm (168 tooth flywheels) $76.66
716019 : Slave Cylinder Spacer $0.00
712500M : Flywheel and Clutch kit for LS-Series / Gen 3 engines $627.21
22-0002 : Power Master: 9509 - Chevy XS Torque Starter $235.00
*715543 : Jeep Wrangler TJ Cable shifter $249.00
CCLS1 : Headers natural steel finish $304.82
R-TJ10H : Radiator, RadLock HD $529.88
FX3300-T : fan and shroud assembly, electric $278.00
*SK2XC : Shifter kit, cable $169.00
Nutserts 6035739 $41.04 6035739: NUT
Skid Plate Bolts 6035836 $22.80 6035836: BOLT-HEX FLANGE HEAD
2002-2006 TJ high-pressure power steering hose GATES Part # 354030 $18.01
Radiator upper - Gates #21833 $7.66
Radiator lower - Napa 7473 or Gates #20842 $4.44
Hurst NV3550 Shifter $209.00
Shift Boot Plastic 53000056AB $16.93
Transmission Mounting Plate: 52058546AB $40.00
Transmission Insulator Bushing: 52058551AB $38.95
Front Driveshaft
Rear Driveshaft $235.00
FUEL RAIL PRESSURE GAUGE ADAPTER $8.99
Summit Racing® Auto Meter Ultra-Lite Analog Gauge Pro Packs 07-0002 $585.70
Autogage Analog Gauges 2180 $36.95
Shifter Seal
ECU Mount $44.95 LS based engine ECU mount - Pirate4x4.Com : 4x4 and Off-Road Forum
Intake
 
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#86 ·
MasterCraft Safety had their harness' on sale so I got a pair for $90 shipped! MasterCraft Rubicon seats later this month, black w/ black center and red side panels. Found a dealer that has them for $260 ea shipped! Will share the source if they are worth dealing with.
 

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#92 ·
New seats sit too high and lean too far forward for my liking. Ordered a spare driver seat riser to replace passenger folding and going to cut 1" out and slight angle back then weld back together.
 
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