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Old 09-19-2010, 08:16 PM   #1
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Engine swap from a 2.5 to a 4.0?

I am looking into swapping out my 2.5 for a 4.0 and I am wondering what other things I should consider? Do I need to get a new transfer case and a new manual trans? I have done an engine swap in a car before but just the same engine...
Any advice?

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Old 09-19-2010, 08:20 PM   #2
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You'll need a new ECM (engine computer), engine wiring harness, transmission, transfer case (or install a new input shaft into your existing transfer case), motor mounts, and new f/r driveshafts in addition to the 4.0L engine.

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Old 09-19-2010, 08:26 PM   #3
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If you don't have alot of money in your jeep sell it and buy one with a 4.0.
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Old 09-19-2010, 08:27 PM   #4
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Quote:
Originally Posted by rbloodhound View Post
If you don't have alot of money in your jeep sell it and buy one with a 4.0.
X2, that is the most cost-effective way to get a 4.0L.
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Old 09-19-2010, 08:34 PM   #5
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Well I would just buy one with a 4.0 but I am only 17 and this is going to be part of my senior graduation project. I am a pretty good mechanic and do this stuff a lot. My hobby. I am not to worried about money because all of the parts r going to be used meaning, the engine, wireing harness, and computer r with the engine I am buying and then I'll buy a the transfer case stuff and drive shaft stuff after.
Can I get a different spline gear for my manual trans? Instead of replacing it?
What r the different size trans and transfer cases?
What jeep 4.0 engines will fit in my TJ?
Sorry for all the questions. It's just a big project!
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Old 09-20-2010, 08:55 AM   #6
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V8 power
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Old 09-20-2010, 09:22 AM   #7
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Quote:
Originally Posted by 97'wrangler View Post
Well I would just buy one with a 4.0 but I am only 17 and this is going to be part of my senior graduation project. I am a pretty good mechanic and do this stuff a lot. My hobby. I am not to worried about money because all of the parts r going to be used meaning, the engine, wireing harness, and computer r with the engine I am buying and then I'll buy a the transfer case stuff and drive shaft stuff after.
Can I get a different spline gear for my manual trans? Instead of replacing it?
What r the different size trans and transfer cases?
What jeep 4.0 engines will fit in my TJ?
Sorry for all the questions. It's just a big project!
Here's another guy telling you it'd be wise to reconsider this project.

but to answer your questions, you need a new transmission, to find out the options as far as transmission/Tcase here are the stock ones:
Stock TJ Specifications - JeepForum.com

a Jeep 4.0 is a Jeep 4.0. they will all "fit" but an engine swap is NOT like it was when your dad was your age. computers have made this type of project VERY time consuming and VERY expensive (even if you buy the parts used). The ECU, transmission, harness, engine must all match...so basically you need a wrecked TJ with a 4.0 as your parts vehicle to make this swap feasable. Again its a project I'd advise against.

I actually agree w/ rbloodhound - if you are going to go through all the trouble, then you might as well change to a V8. but then you will definitely need a different rearend as well...your D35 won't cut it.

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