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Old 05-21-2012, 05:27 PM   #1
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Question TJ 2.5L to 4.0L swap questions

Hi everybody I've been a lurker on here for a while and finally broke down and joined today. I need to pick some brains on this one... I'm swapping my 1997 TJ's 2.5L and frame (rusty) for a 1998 TJ 4.0L with frame. I have engine, auto trans (I'm not happy about it either), no t-case (except my 2.5L's ax-5 and 231), and no engine accessories. I do have the harness, pcm, and shifter with linkage. My questions are:
Will my 2.5L brackets and accesories fit on the 4.0L?
Does anyone know the difference between the spline count on the input shaft of the t-case?
Also anyone have a 4.0L with 35's and 4.10's? I'm curious to know what your rpm's are at highway speeds.

Thanks for your time I'm sure I'll have more ?'s but this will point me in the right direction. Don't worry pics are in the works...

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Old 05-21-2012, 05:43 PM   #2
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Someone might also need to tell me how to upload pics cause I read the faq and I don't see a link that says pictures and albums in the usercp

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Old 05-21-2012, 05:47 PM   #3
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Great question.I want to do the same thing in my 06
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Old 05-21-2012, 05:54 PM   #4
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So why do you think you can't use your 231 TC? It's used with with the 2.5 and 4.0.
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Old 05-21-2012, 05:58 PM   #5
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here are a few links to get you started, if you werent swapping frames as well I would say dont try it, but swapping frames is the best way to do this swap.

2.5 to 4.0 swap

Jeep TJ boot camp

Gear chart with links to other speed / gear sites
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Old 06-07-2012, 09:18 AM   #6
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Thanks for the input, I got a 231j from the junkyard and swapped in the 23 spline input shaft and bolted it up everything fits. Now I need to find an AX-15 because I'm not feeling the automatic thats with my 4.0L frame. I'll live with it if I have too but would prefer not to. Local boneyard has a lead on one in Ohio for $600 but would rather find someone looking for a swap locally. All the accessories fit as well the only difference I've found is a small lower brace for the alternator that is different I'll just make one from some flat steel til i find one in the junkyard. The 2.5L power steering pump while different than a stock 4.0L's will work.
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Old 07-11-2012, 05:25 PM   #7
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Ok all together again now no spark no fuel and no bus any ideas?
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Old 10-21-2012, 10:12 PM   #8
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just did it

Quote:
Originally Posted by 1997TJv2.0 View Post
Hi everybody I've been a lurker on here for a while and finally broke down and joined today. I need to pick some brains on this one... I'm swapping my 1997 TJ's 2.5L and frame (rusty) for a 1998 TJ 4.0L with frame. I have engine, auto trans (I'm not happy about it either), no t-case (except my 2.5L's ax-5 and 231), and no engine accessories. I do have the harness, pcm, and shifter with linkage. My questions are:
Will my 2.5L brackets and accesories fit on the 4.0L?
Does anyone know the difference between the spline count on the input shaft of the t-case?
Also anyone have a 4.0L with 35's and 4.10's? I'm curious to know what your rpm's are at highway speeds.

Thanks for your time I'm sure I'll have more ?'s but this will point me in the right direction. Don't worry pics are in the works...
I wanted to do the same thing on my jeep and today I did. I bought the reservoir from a 4.0 TJ online and attached it to my 2.5L pump. I had to get rid off the tube coming out of my pump and widen it with a 3/4 bit (be careful if you go to far in the rubber O ring that comes with the reservoir might leak. it didn't happen to me, I was very careful with measurements) Then you will need to bend the high pressure hose (where it attaches to the pump) to make it reach. And the return hose you need to get a longer hose from the auto parts store. I hope this works for you and anyone else that wants to do the same. Good luck.
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Old 10-21-2012, 10:24 PM   #9
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I want to do the same thing in my 06

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2.5l , 4.0l , 4.0l swap , swap , wrangler tj

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