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Old 03-15-2008, 05:00 PM   #1
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2.5l swap to 4.0l

i want to swap my anemic 2.5l with a more substantial and powerful setup

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Old 03-15-2008, 05:03 PM   #2
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ok go for it.....

or are you asking how to do it?

and if so...... what info are you lookin for??


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Old 03-15-2008, 05:03 PM   #3
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i am in dire need of knowing cost and the level of involvement in this swap i am talkaing everything... i plan on buying a re manufactured 4.0l and an ax-15 tranny. i imagine i will have to replace the transfer case too. but any insight,wisdom, help would be awsome
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Old 03-15-2008, 05:15 PM   #4
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reman motor = about $1300 ...here.....
http://www.jeepenginesales.com/Jeep_...mc-242lb-1.php

reman AX-15 = $1200.... here.....
http://www.discountjeepparts.com/ind...0_508_502_3679

you will need the wiring harness and computer for the 4.0 tranfer case/ transmission...skid plate/crossmember.

most rebuild engines are just the motor. so....you will need everything else that bolts to it... intake, oil pan, alternator, motor mounts, and so on..

need to know anything else? just ask.

it will most likely be in your favor to find a 4.0 with wiring harness fro a junk yard.. alot cheaper.


and as far as the level of involvement....your guttin your jeep and replacing the entire drivetrain so the involvement is pretty high if you haven't done thing type of wrenching before..

but don't let that scare you away .....anyone can wrench....you only learn if you try.
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Old 03-15-2008, 05:22 PM   #5
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thanks alot for all that info, this will really be my first major project but i have a bit of experience with a wrench so i am not really as afraid of my ability as i am afraid of what financial blow it will take
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Old 03-15-2008, 05:32 PM   #6
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yeah anyboy can turn a wrench but money is alway the factor.

if money is a big factor....and it usaully is.... i suggest you try and find one in a junk yard. the 4.0 and tranny can also be found in cherokee's, and be the easiest to find. It's getting pretty hard to find wrangler parts in any junkyard.

good luck and keep us updated with your decision.
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Old 03-15-2008, 05:34 PM   #7
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Might be worth the time to look for a similar year Jeep w/ a bad 4.0 to scavenge all the misc parts from, almost certain to be cheaper than running to the dealer or even a junk yard every time you need something..
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Old 03-15-2008, 05:42 PM   #8
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Good thread...I was about to make the exact same thread here in a few minutes. Guess I don't have to now. Will the tranny on my 2.5L bolt up to the 4.0L or will I need a new tranny too? Just curious.

Thanks!
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Old 03-15-2008, 05:48 PM   #9
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Originally Posted by HighTechRedneck View Post
Good thread...I was about to make the exact same thread here in a few minutes. Guess I don't have to now. Will the tranny on my 2.5L bolt up to the 4.0L or will I need a new tranny too? Just curious.

Thanks!
dont think it will but i'll try to check on that for you
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Old 03-15-2008, 06:51 PM   #10
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Even if it would bolt up the ax-5 is to weak for the 4.0
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Old 03-15-2008, 07:20 PM   #11
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all kinds of great info here, ax-5 is no go. finding a complete motor from bone yard is most effective, and you can find them with intact wiring harnesses if you ask. finding a donor jeep is a great idea, but its hard to find even a dirt cheap yj for a donor. i'm pretty sure there is some fabrication on motor mounts, to go from 4 cyl to 4.0L. i think they have to be moved forward.

i'm curious about the engine wiring harness, connecting to the dash harness, i posted a thread about this and nobody has responded. i think they might be interchangeable for similar year, i wanna go with dramatically different years. or you have to get an under dash harness for same yj that engine you are using

build a stroker, and tell me how it goes
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Old 03-15-2008, 10:26 PM   #12
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well from what i understand the ax15 is 2 inches overall longer than the ax5 so that means the t case would have to be moved back 2 inches...but also the t case is a 21 spline for to mate with the ax5 so i would either have to swap t cases or rebuild with a 23 spline as that is what the ax 15 is...also that would bring about needing new front and rear driveshafts...correct...man that is so much denero..... my jeep has 167,000 but did run like a top. then i did something stupid and let it overheat so now i need a new engine...but i jsut test drove an 06 rubicon today for the fun of it and i loved it.. the 4.0 kicks the 2.5 butt,
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Old 03-15-2008, 10:28 PM   #13
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well from what i understand the ax15 is 2 inches overall longer than the ax5 so that means the t case would have to be moved back 2 inches...but also the t case is a 21 spline for to mate with the ax5 so i would either have to swap t cases or rebuild with a 23 spline as that is what the ax 15 is...also that would bring about needing new front and rear driveshafts...correct...man that is so much denero..... my jeep has 167,000 but did run like a top. then i did something stupid and let it overheat so now i need a new engine...but i jsut test drove an 06 rubicon today for the fun of it and i loved it.. the 4.0 kicks the 2.5 butt,
honestly it is easier to find a jeep with a 4.0 instead of swap. but most people can't let go of their jeep.
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Old 03-15-2008, 10:31 PM   #14
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well it is my first jeep and i am going to college this fall...so this is the jeep i bought so it is what i have to deal with.. i am working the rest of the year till the end of august, buying another jeep is out of the question and i just want to finish what i started with this one.
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Old 03-18-2008, 06:42 AM   #15
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anybody...what is the advise on buying used jeep engines, i am dieing for a 4.0 found a used one and can get whole drivetrain including driveshafts for around 1500 and they all have like 102k on them, is that bad, am i buying someone else's problems????????????????need help
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Old 03-18-2008, 08:56 AM   #16
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That's part of the problem with buying from a junk yard, you can only take the yard owners word so far as what you're getting. I always budget for junkyard motors and drive trains. I always put asside at least 25% of the cost of the buy for repairs or replacement of warn parts. Example, a $1500 buy, i would try to have around $400 or so set aside to replace anything you might need to. Sometimes that's not enough, but it gives you a good start. Sometimes you won't need any of it and you have 400 to spend else where. If you only have $1500 to spend on the buy, then try to talk the yard down to around 1200 for the deal, that leaves you your 25% for parts. This is just what I always do. Good luck and keep posting updates.
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Old 03-18-2008, 04:21 PM   #17
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well, not sure if it is the wisest thing, but i may buy the engine and tranny from an e-bay user. if 100,000k sounds like too much on the engine than someone say something, cause i jsut cannot take that little 2.5 anymore, and i am keeping the jeep so, this transplant is it, only unless there are other ideas!
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Old 03-18-2008, 08:53 PM   #18
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are you getting complete, unmutilated wiring harness, and computer also? some accessories will probably be different, to. you're almost guaranteed to have to spend more money to make it come alive.
100k isn't too many miles, it ain't new, but it will last forever if taken care of.
good luck
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Old 03-18-2008, 10:06 PM   #19
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well to be honest it is kind of a gamble i won't see the engine untill it gets here. it will most likely be shipped form out of state, junkyards around here want way too much for them, so i don't know what the shape of the wiring is all i know is it comes with the wire harness and comp!!!
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Old 03-19-2008, 08:06 PM   #20
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alright i think i am getting everything the engine the tranny and transfer case, all with 100,000 on them i don't know about the clutch assembly and if i can retain any of the 2.5l clutch assembly also i am lost about the motor mount, is it jsut a matter of measuring them or what??????????????
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Old 03-19-2008, 08:09 PM   #21
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i believe where the mount is located on your frame has to be cut out, and rewelded a couple inches forward. definately gonna require someone with some fab skills, don't cut corners here. i'd say replace the clutch while you're here, and i don't think the clutches are the same.
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Old 03-19-2008, 08:34 PM   #22
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i have a buddy that is big into vws' and he welds alot, so he said he would help out. i gotta find the crossmeber and some drive shafts and i think i am set the engine has everything, valve cover to oil pan and i guess its just a matter of getting it in, this weekend i am gonna gut the jeep and try to get it ready
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Old 10-12-2008, 06:37 PM   #23
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What no update on the swap? I was really getting into the drama here. Now I can't sleep tonight wondering if he got the rubber to the road.
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Old 10-12-2008, 06:59 PM   #24
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what is this? where's the rest of thre thread????
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Old 10-12-2008, 08:53 PM   #25
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What no update on the swap? I was really getting into the drama here. Now I can't sleep tonight wondering if he got the rubber to the road.
damn son, the rubber missed the road and ended up on the dirt 7 months later she just never got finished and now she is gone, although i still ahve a nice cj play toy...mmm ill start a build thread on that now...

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