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Old 04-06-2011, 09:30 PM   #1
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2.5L to 4.0L swap

Hey guys,

If i had a donor 4.0L engine from another wrangler, what else would I need in terms of parts to finish the installation. We have a close family friend that used to specialize in Jeep repairs and I can find an engine pretty easily, so that saves me a lot. But what should I expect in this swap?

Thanks!

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Old 04-07-2011, 01:58 AM   #2
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if your going to bother with an engine swap go for a V8. Going from the 2.5 to the 4.0l requires just as much if not more work and $. The gains from swapping to the 4.0l just dont justify the costs and effort. Heck i got a stock 4.0L and wish I had a v8.

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Old 04-07-2011, 04:12 AM   #3
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^^^thats not necessarily true. He said most of his parts are free anyways. And it's hard to find a v8 that's as durable as the I6. Also, IMO if you put a v8 ford 8.8 axles new transfer case and other stuff. Your not "moding" your jeep. Your just making it not a jeep anymore. Whereas D44's come on jeeps. I6 4.0l come on jeeps. So your still just upgrading your jeep...anyways biggest problem I would think would be matching tranny to engine.
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Old 04-07-2011, 09:29 AM   #4
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^^^thats not necessarily true. He said most of his parts are free anyways. And it's hard to find a v8 that's as durable as the I6. Also, IMO if you put a v8 ford 8.8 axles new transfer case and other stuff. Your not "moding" your jeep. Your just making it not a jeep anymore. Whereas D44's come on jeeps. I6 4.0l come on jeeps. So your still just upgrading your jeep...anyways biggest problem I would think would be matching tranny to engine.
AGREED...

You'll have to swap out the tranny for an AX-15(5spd) or NV3550(5spd) or NSG370(6spd) (manual options) or a 32rh or 43rle (auto options)
You MAY have to swap out the transfer case too... if you dont have AT LEAST a NP231...
I BELIEVE this also will require a new drive shaft (or 2... 1 for the front)

Do a quick search on the forum... maybe there is a build thread for this mod/upgrade
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Old 04-07-2011, 01:22 PM   #5
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AGREED...
Thank you! I usually get my ass chewed on when I mention this idea of mine.
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Old 04-07-2011, 01:56 PM   #6
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Yeah i hear you... im keeping mine Jeep...

going with the HP D30 (From a Jeep Cherokee) in the front and a D44 in the rear... you wont catch me putting Ford's mistakes (circled in blue) on my Jeep... Only stuff that either came ON a Jeep or made FOR a Jeep...

AND i will be keeping the main portion of the Jeep... not going to chop it up to a buggy...
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Old 04-07-2011, 03:24 PM   #7
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Yeah i hear you... im keeping mine Jeep...

going with the HP D30 (From a Jeep Cherokee) in the front and a D44 in the rear... you wont catch me putting Ford's mistakes (circled in blue) on my Jeep... Only stuff that either came ON a Jeep or made FOR a Jeep...

AND i will be keeping the main portion of the Jeep... not going to chop it up to a buggy...
Keeping it jeep? Let's say he uses an amc v8 wouldn't that be jeep! Or what about a magnum 5.9 they are owned by chrysler after all! The axles under that jeep are made by dana as are lot's of brands! The hp44 out of the 70's ford's are far superior to any axle that ever came in the front of a jeep!

It's about building a better vehicle then the factory did. It makes no sense to me why anyone would bash the idea of putting better then factory parts in and not having delusions of purity being the best thing!
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Old 04-07-2011, 03:36 PM   #8
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^^^told you. Lol
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Old 04-07-2011, 03:39 PM   #9
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What I find funny about brand bashers is they usually have never even owned the very thing they are knocking! I have wheeled Fords, Chevys,dodges and jeeps and can tell you there isn't a single one that doesn't have it's shortcomings.

I would also suggest the v8 swap! I have owned four banger and four liter tj's, but the onlyengine I have actually been impressed with is my 5.9 .
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Old 04-07-2011, 03:40 PM   #10
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Keeping it jeep? Let's say he uses an amc v8 wouldn't that be jeep! Or what about a magnum 5.9 they are owned by chrysler after all! The axles under that jeep are made by dana as are lot's of brands! The hp44 out of the 70's ford's are far superior to any axle that ever came in the front of a jeep!

It's about building a better vehicle then the factory did. It makes no sense to me why anyone would bash the idea of putting better then factory parts in and not having delusions of purity being the best thing!
easy there firecracker... not lighting any fuses here... nobody is bashing ANYbody... we only discussed people (such as yourself) who bash US for trying to "keep it Jeep"... i was simply stating an opinion... after all, along with preference, that's what this forum is full of... opinions...
big whoop you like fords... i dont... if it wasnt for the I6 or the Wrangler TJ (or YJ/CJ/Willy's) i wouldnt give a crap about Chrysler either...
As far as your "building a better vehicle than the factory did" comment... i wasnt let it on that little secret... all i know is that its about EXPERIENCE not equipment... i can hang pretty good with my stock Jeep (ask the guys I go out with)
You seem to be younger, because if you werent you would understand I'm going for the classic style more than modern... This Jeep is the first car my wife had/learned to drive... and i wish to share that with my kids some day... if i chop it up and add all of this stuff, then I, in my own opinion, believe takes away from that..
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Old 04-07-2011, 03:41 PM   #11
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What I find funny about brand bashers is they usually have never even owned the very thing they are knocking! I have wheeled Fords, Chevys,dodges and jeeps and can tell you there isn't a single one that doesn't have it's shortcomings.

I would also suggest the v8 swap! I have owned four banger and four liter tj's, but the onlyengine I have actually been impressed with is my 5.9 .
yeah and you are also from MI, where apparently, they know E V E R Y thing...
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Old 04-07-2011, 03:42 PM   #12
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^^^told you. Lol
yeah yeah i see...
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Old 04-07-2011, 03:46 PM   #13
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"LOOOOOUDDD NOIIIIISSEESSS!!!!!"






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Old 04-07-2011, 03:52 PM   #14
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Btw. I'm 19 and interested in keeping my Tj a Tj.
And love diving (for the OP)
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Old 04-07-2011, 03:53 PM   #15
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Btw. I'm 19 and interested in keeping my Tj a Tj.
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Old 04-07-2011, 03:53 PM   #16
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I know I have scattered an inline six racing in the sand! Not so unbreakable after all. Let me put it like this the only thing I ever broke on my old 78 bronco with the 429 dove motor was the front dana shafts!
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Old 04-07-2011, 03:55 PM   #17
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I think this is appropriate here:
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Old 04-07-2011, 03:58 PM   #18
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If you are stuck on a 4.0 you will need the pcm, harness, frame mounts, new transmission and a 23 spline input for your transfer case you will also need the 6 cyl radiator shrouded!
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Old 04-07-2011, 03:58 PM   #19
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I know I have scattered an inline six racing in the sand! Not so unbreakable after all. Let me put it like this the only thing I ever broke on my old 78 bronco with the 429 dove motor was the front dana shafts!
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Old 04-07-2011, 04:02 PM   #20
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I love ford to! Owned 2 of them. I tried my damnedest to run my 99 ford explorer into the dirt so I'd have an excuse to buy a jeep. All I managed to do was wear out the struts and break the A/C. That was at THREEHUNDREDTHOUSANDMILES. But I bought a jeep. Because I love jeeps. The d44 is a raw ass axle. And the I6 is solid as a rock. The transfercase on my rubicon is 4:1! It's just something I thought you might want to consider.
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Old 04-07-2011, 04:33 PM   #21
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All I am saying is it is money better spent to do a v8. I say this with experience on the matter. I have been building cars and trucks since I was 15 and am 34 now .
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Old 04-07-2011, 04:35 PM   #22
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Envious the op lives about 45 minutes from the rubicon trail!
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Old 04-07-2011, 04:51 PM   #23
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Old 04-07-2011, 05:00 PM   #24
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Don't forget you will need the same year or newer engine with all the smog equipment that came on that engine for the model year of the engine to meet emissions in the 916.
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Old 04-07-2011, 05:23 PM   #25
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maybe a 4.0 then a stroker kit? then you have a brand new motor. just and idea dont shoot!!
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Old 04-29-2011, 01:55 PM   #26
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I dont mean to hi-jack thread, but I think it's relevant...

I'm not sure if it's just my area (urban Nevada), but not all areas allow the V8 swap. I have a 2.5L and want to upgrade, and in Clark County (Las Vegas) and Washoe County (Reno) you can only do motor swaps with motors that were an option for that exact model year. So, 2.5L or 4.0L only! Kind of crappy. So, almost every 2.5 to 4.0 swap turns into a "don't go 4.0, go V8" which isn't a luxury that all have.

My dilemma:
I have a 2000 2.5L manual and have access to a complete wrecked donor vehicle (side damage) that's a 2003 4.0L auto. I am considering doing the swap since I was quote $1500 and take whatever I need for my swap, I just dont know what I need to all grab. It's a one-time, get it while you can kind of deal so I need a complete parts list. Can anyone help me out? Please reply or PM me.

Thanks!
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Old 04-29-2011, 06:44 PM   #27
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You will need a pcm with the same bus as the 2000 and the 03 pcm won't work if you want to stay five speed then you will need a transmission if not you will likely need a older non overdrive trans due to the pcm controlling it. You will also need the shift cable and floor shifter assembly including the floor pan the shifter mounts to . Or I guess you could just take the whole dash and cluster with all the wiring for the dash, engine and the pdc on the fender. You could swap in a 4.7 from a 2000 grand limited. They are both jeeps and the same model year so should have no problem passing an inspection in Nevada!

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