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Old 05-28-2011, 11:18 AM   #1
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Question 4.2 to 4.0 tranny question

PLEASE HELP! Ok, I am in the middle of doing the 4.2 to 4.0 swap on my 1990 YJ. I found a 1992 Cherokee 4X2 as a donor. I am ready to drop the new enigine but have run into trouble. I can not find a pilot bushing to mate the 1990 YJ tranny and the 4.0. The pilot bushing out of the 4.2 has the correct inside diameter but the outside is a bit to big. The 4.0 pilot bushing from NAPA is even bigger than what I started with from the 4.2. I went to the local Jeep dealer and they gave me a pilot bearing that fit the 4.0 but the inside diameter was way to big for the tranny. I filed down the 4.2 pilot bushing and got it pressed in the 4.0 but I am just affraid that it is not perfectly square anymore. Is there a conversion pilot bushing or should I just get another bushing and take it to a machine shop and have it properly filed down to fit? Any other sugestion?

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Old 05-28-2011, 04:18 PM   #2
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size matters

Get the dimension you need, inside diameter, outside diameter and width. And buy one by dimensions. Most parts stores have a book somewhere with dimension listed. Dial calipers are great for measuring this problem.

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Old 05-29-2011, 12:35 PM   #3
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Thanks for the suggestion, I treid looking into searching by deminision but nobody has there bearing listed by dimensions. O'Reailey was the only shop that even had dimensions listed but nothing that worked for my application. My only thought now is to go to the machine shop and have the over sized bushing taken down a few mil. Thoughts? I know there has to be someone who has had this problem.
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Old 06-12-2011, 12:55 PM   #4
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I finailly got the engine stabbed in. I had to have a pilot bushing made. I took the big bushing from the 1992 Cherokee (Dealer p.n. 1-53009180AB and a pilot bushing from Napa p.n. B128) I Napa bushing fit my input shaft and the Mopar bushing fit the crank shaft. I took the 2 bushings to a machine shop and had the bigger bushing bored out about 10/1000s. Pressed the smaller bushing into the bigger one. Tada!
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Old 05-14-2012, 10:02 AM   #5
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Sweet I'm doing a similar swap exept I dumped the b10/5 and installing a nv3500
The output shaft is too big. I hope mine has a bushing in there. Guess I'm going to get one made also.
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