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Old 02-14-2008, 01:39 AM   #1
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Stroker?

Ok, a v8 isn't in the budget because of all the parts and labor involved. What about pulling a 4.0L off a tj and having a friend in auto school(Or me if I decide not to go to a university and go to community college instead) stroke it to a 4.8L?
1. Will stock axles hold up?
2. Will I still want to re-gear from 3.73?
3. Will the stock tranny hold up?
4. Is there anything else that would need to be replaced?
5. Any idea of an approximate cost to go from 2.5L to 4.8L?

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Old 02-14-2008, 09:38 AM   #2
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you have the D35 and 33's??
i think that will hold up to a 4.8L, but you'll have to be carefull not to do burnouts and back wayy of the gas when off road
you wont need to regear althouhg you may want to, i have 35's and the 4.0 and i dont mind so you'll be way better off then me
the stock tranny will hold up i think, but a manual would be better
you may need to replace the computer if you switch engines but im not positive
cost well lets assume you can get a 4.0 with all the wiring and computer for 2K and your friend works for free??? i would say about 600 on top of those two things, but it will mostly be the original engine with all things including computer and then lots and lots of time

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Old 02-14-2008, 10:12 AM   #3
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if you have to purchase a 4.0 from the start (if you have a 2.5L), it's not going to be cheap. the stoker kits run about $1500 or so not including other doo-dads you'll need to deal with to do that mod, and that is not including all the costs of swapping a 4.0L in place of your 2.5L. the 4.0L is not going to bolt up to your AX5, nor would that tranny be able to handle the extra power of a stock 4.0L, muchless that of a stroked 4.0L.

i've heard and read about people breaking their d35s in one way or another on the street, so yeah, i could see that being a weak link with a 260hp motor in front of it. you would probably be ok for a while, but i wouldn't expect it to last very long.

i'm definitely not trying to convince you not to do it by anything i've written, but i would add up the costs. it won't be cheap.
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Old 02-14-2008, 03:03 PM   #4
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my friend just got a 4l for 100 bucks at a junk yard and is doing the same thing. we'll see how it goes. more opinions please
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Old 02-14-2008, 03:12 PM   #5
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So what did he pay for a different transmission, harnesses, etc? Those 'hidden' costs need to be factored in as well. The AX-5 behind the 2.5L (assuming manual) will NOT hold up to the 4.0, even in stock form, let alone fit.
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Old 02-14-2008, 03:28 PM   #6
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$100 for a 4.0L is a great price. you might as well do a full rebuild with a junkyard motor while you're stroking it to avoid hidden problems down the road. with just getting the motor alone, you will need to be sure of the year so you can properly match a wiring harness and computer and some other parts. while not many, there were some differences in the 4.0L over the years....mainly with the harness and comp.

the stroker kits start at $2400 and go up from there. plus the cost of the engine, the wiring harness and computer (if you engine doesn't come with them), new motor mounts, transmission, either new tcase or a change of input shaft on yours (different spline count), new radiator to cool your V8 powered 6cyl., driveshaft changes or mods, exhaust mods, and not to mention any d35 issues you will encounter at some point shortly after the stroking.

like i said before, i'm not trying to tell you not to do it, but doing a 4.0L swap is expensive as it is, then stroking it about doubles that. you're talking way over the price of doing a V8 swap.
i can get a late model, low mileage LS1 with harness and comp. for $2000 locally....only mentioned as a reference point. swapping in a LS1 or any other SBC engine is no small task, but it really wouldn't be all that more than what you would go through to do that swap.
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Old 02-14-2008, 07:03 PM   #7
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Originally Posted by TXST8tj View Post
$100 for a 4.0L is a great price. you might as well do a full rebuild with a junkyard motor while you're stroking it to avoid hidden problems down the road. with just getting the motor alone, you will need to be sure of the year so you can properly match a wiring harness and computer and some other parts. while not many, there were some differences in the 4.0L over the years....mainly with the harness and comp.

the stroker kits start at $2400 and go up from there. plus the cost of the engine, the wiring harness and computer (if you engine doesn't come with them), new motor mounts, transmission, either new tcase or a change of input shaft on yours (different spline count), new radiator to cool your V8 powered 6cyl., driveshaft changes or mods, exhaust mods, and not to mention any d35 issues you will encounter at some point shortly after the stroking.

like i said before, i'm not trying to tell you not to do it, but doing a 4.0L swap is expensive as it is, then stroking it about doubles that. you're talking way over the price of doing a V8 swap.
i can get a late model, low mileage LS1 with harness and comp. for $2000 locally....only mentioned as a reference point. swapping in a LS1 or any other SBC engine is no small task, but it really wouldn't be all that more than what you would go through to do that swap.
Hmm, I don't see this happening any time soon. maybe after college when I'm a ceo for some company. I guess I'm doing a re-gear. Thanks guys
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Old 02-15-2008, 08:30 AM   #8
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Originally Posted by tobycat1 View Post
Hmm, I don't see this happening any time soon. maybe after college when I'm a ceo for some company. I guess I'm doing a re-gear. Thanks guys
hehe...yeah, it doesn't take much to get the project costing a bunch of money. i had actually been looking into swapping in a 4.0L myself and i was made aware of all the extra stuff you have to go through to get it done. swapping in a 4.0L is still something i am considering as far as engines swaps go, but i figure i would pretty much have to find a complete drivetrain at the right price for it to be worth it. a V8 would be awesome, but with the right gearing, the 4.0L is all i will probably need. now if it is going to cost loads of money to swap a 6cyl in when you start talking about stroking it, you might as well just do a V8.

if you already had the 4.0L in place, that's a different story. it would be far easier and cheaper in the end to stroke it for that extra power. setting the engine up (and everything that entails) in stock form is an ordeal in itself. then adding a the stroker kit that costs as much as a complete V8 would, just kinda throws that out the window in my book.
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Old 02-15-2008, 07:29 PM   #9
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Look, Im not trying to discredit anyone here but none of you really know what your talking about. I am personally stroking a 4.0L myself at this very moment and have done countless hours of research on what you need to make this work. First and formost DO NOT BUY A STROKER KIT! That is the biggest flush of money ever. It can be done for literally a fraction of the cost of those kits. Second, almost every junkyard around will offer a rebuildable core engine for about $100. If you cant find one there than look for a rolled Jeep with one and you can purchase it cheap from there as well. Ebay also has GREAT deals on complete 4.0L engines. Moving on after you get that stuff, you need to know you can not get a 4.8L out of it without spending the large amoutn of money your were talking about. This is because stroking a 4.0L to that size requires new custom made pistons and extensive machining. But, the good news is you can effectively get a 4.0L to a 4.6 or 4.7L for much cheaper. The greatest part is you can put together your own custom stroker kit by simply using many factory parts. You will need to pull a few parts from a 4.2L (258) engine. These came stock in many YJ's and CJ's Here is a list of what you'll need:
-4.2L crankshaft
-4.2L connecting rods
-4.0L Cherokee HO (high output) engine (best engine for a stroker)
-Speed Pro Hypereutectic pistons (.030" over bore)
-Crane Cam part # 753905
-3 way valve job
-engine decked and bored
-head resurfaced if needed
-full gasket set
-brass freeze plugs
-24lb./hr Ford Racing injectors
-Wolverine hi-torque pushrods
-federal mogul piston ring set
-head gasket matched port and polish (DO NOT POLISH THE INTAKE SIDE!)
The rest would just be various little things you would want, like spark plugs, wires, distributor, and whatever else. Id also suggest getting a Melling high volume oil pump when doing a stroker build but it isnt mandatory, although failry cheap. Also a new water pump may be needed for this application and Id say go with a Flowkooler high volume water pump for that. IF you wanted new paint for the block and stuff Id suggest getting Durabak engine enamel, it comes in a lot of colors and is about $20 for a quart.
Anyway, if you keep your eyes open for deals and dont look around a little you can do all this for about $650-700 total. A few other things could need replacing but you wouldnt know until you cracked it open, such as new timing set and maybe valve springs. Also, if you have a buddy like I do who has a few of these things laying around you can get a better deal on them too. But watch Ebay for some of that stuff. Also, all you need to get it under the hood would be a new set of motor mounts really. Besides the tranny hook ups. But the stock drivetrain WILL hold up to this if you are careful. You dont have to drive like a grandma but just dont do any street racing either. Stock, the 4.0L puts out about about 190hp and after this build it will push 250hp and maybe even a little more if your lucky. Its not as bad as everyone is saying really. Then you would need a 4.0L computer and wiring harness to hook it all up. Another great thing is, the computer still thinks you got the stock 4.0L sitting under there. For a little more power you can spend a few hundred more bucks and get and intake, headers, bored throttle body, electric fan conversion, and an exhaust. That would push you to about 270 hp probably. After that you may need to start worrying about the drivetrain though. And I would deff. suggest going with MORE bomb proof motor mounts for this application. If you would like for information and help just pm me.
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Old 02-15-2008, 08:08 PM   #10
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Originally Posted by GrnTJ View Post
Look, Im not trying to discredit anyone here but none of you really know what your talking about. I am personally stroking a 4.0L myself at this very moment and have done countless hours of research on what you need to make this work. First and formost DO NOT BUY A STROKER KIT! That is the biggest flush of money ever. It can be done for literally a fraction of the cost of those kits. Second, almost every junkyard around will offer a rebuildable core engine for about $100. If you cant find one there than look for a rolled Jeep with one and you can purchase it cheap from there as well. Ebay also has GREAT deals on complete 4.0L engines. Moving on after you get that stuff, you need to know you can not get a 4.8L out of it without spending the large amoutn of money your were talking about. This is because stroking a 4.0L to that size requires new custom made pistons and extensive machining. But, the good news is you can effectively get a 4.0L to a 4.6 or 4.7L for much cheaper. The greatest part is you can put together your own custom stroker kit by simply using many factory parts. You will need to pull a few parts from a 4.2L (258) engine. These came stock in many YJ's and CJ's Here is a list of what you'll need:
-4.2L crankshaft
-4.2L connecting rods
-4.0L Cherokee HO (high output) engine (best engine for a stroker)
-Speed Pro Hypereutectic pistons (.030" over bore)
-Crane Cam part # 753905
-3 way valve job
-engine decked and bored
-head resurfaced if needed
-full gasket set
-brass freeze plugs
-24lb./hr Ford Racing injectors
-Wolverine hi-torque pushrods
-federal mogul piston ring set
-head gasket matched port and polish (DO NOT POLISH THE INTAKE SIDE!)
The rest would just be various little things you would want, like spark plugs, wires, distributor, and whatever else. Id also suggest getting a Melling high volume oil pump when doing a stroker build but it isnt mandatory, although failry cheap. Also a new water pump may be needed for this application and Id say go with a Flowkooler high volume water pump for that. IF you wanted new paint for the block and stuff Id suggest getting Durabak engine enamel, it comes in a lot of colors and is about $20 for a quart.
Anyway, if you keep your eyes open for deals and dont look around a little you can do all this for about $650-700 total. A few other things could need replacing but you wouldnt know until you cracked it open, such as new timing set and maybe valve springs. Also, if you have a buddy like I do who has a few of these things laying around you can get a better deal on them too. But watch Ebay for some of that stuff. Also, all you need to get it under the hood would be a new set of motor mounts really. Besides the tranny hook ups. But the stock drivetrain WILL hold up to this if you are careful. You dont have to drive like a grandma but just dont do any street racing either. Stock, the 4.0L puts out about about 190hp and after this build it will push 250hp and maybe even a little more if your lucky. Its not as bad as everyone is saying really. Then you would need a 4.0L computer and wiring harness to hook it all up. Another great thing is, the computer still thinks you got the stock 4.0L sitting under there. For a little more power you can spend a few hundred more bucks and get and intake, headers, bored throttle body, electric fan conversion, and an exhaust. That would push you to about 270 hp probably. After that you may need to start worrying about the drivetrain though. And I would deff. suggest going with MORE bomb proof motor mounts for this application. If you would like for information and help just pm me.
You are talking just engine here you kinda brushed aside the cost of transmission(if i read previous posts properly his will not work)the cost of computer for the 4.0 ,paint and misc. parts-I think your still looking at a large chunk O money for a college student?
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Old 02-15-2008, 08:12 PM   #11
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Now if jack would turn on the rep system I'd give you +rep grn.

Think his point was you can do it for cheaper by building the kit your self?

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Old 02-15-2008, 09:10 PM   #12
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Hmmm... the tranny is the big hang up, anyone else know if it will hold up, or should I just w8 till the tranny needs replacing anyways to do this?
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Old 02-15-2008, 09:10 PM   #13
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Originally Posted by GrnTJ View Post
Look, Im not trying to discredit anyone here but none of you really know what your talking about. I am personally stroking a 4.0L myself at this very moment and have done countless hours of research on what you need to make this work. First and formost DO NOT BUY A STROKER KIT! That is the biggest flush of money ever. It can be done for literally a fraction of the cost of those kits. Second, almost every junkyard around will offer a rebuildable core engine for about $100. If you cant find one there than look for a rolled Jeep with one and you can purchase it cheap from there as well. Ebay also has GREAT deals on complete 4.0L engines. Moving on after you get that stuff, you need to know you can not get a 4.8L out of it without spending the large amoutn of money your were talking about. This is because stroking a 4.0L to that size requires new custom made pistons and extensive machining. But, the good news is you can effectively get a 4.0L to a 4.6 or 4.7L for much cheaper. The greatest part is you can put together your own custom stroker kit by simply using many factory parts. You will need to pull a few parts from a 4.2L (258) engine. These came stock in many YJ's and CJ's Here is a list of what you'll need:
-4.2L crankshaft
-4.2L connecting rods
-4.0L Cherokee HO (high output) engine (best engine for a stroker)
-Speed Pro Hypereutectic pistons (.030" over bore)
-Crane Cam part # 753905
-3 way valve job
-engine decked and bored
-head resurfaced if needed
-full gasket set
-brass freeze plugs
-24lb./hr Ford Racing injectors
-Wolverine hi-torque pushrods
-federal mogul piston ring set
-head gasket matched port and polish (DO NOT POLISH THE INTAKE SIDE!)
The rest would just be various little things you would want, like spark plugs, wires, distributor, and whatever else. Id also suggest getting a Melling high volume oil pump when doing a stroker build but it isnt mandatory, although failry cheap. Also a new water pump may be needed for this application and Id say go with a Flowkooler high volume water pump for that. IF you wanted new paint for the block and stuff Id suggest getting Durabak engine enamel, it comes in a lot of colors and is about $20 for a quart.
Anyway, if you keep your eyes open for deals and dont look around a little you can do all this for about $650-700 total. A few other things could need replacing but you wouldnt know until you cracked it open, such as new timing set and maybe valve springs. Also, if you have a buddy like I do who has a few of these things laying around you can get a better deal on them too. But watch Ebay for some of that stuff. Also, all you need to get it under the hood would be a new set of motor mounts really. Besides the tranny hook ups. But the stock drivetrain WILL hold up to this if you are careful. You dont have to drive like a grandma but just dont do any street racing either. Stock, the 4.0L puts out about about 190hp and after this build it will push 250hp and maybe even a little more if your lucky. Its not as bad as everyone is saying really. Then you would need a 4.0L computer and wiring harness to hook it all up. Another great thing is, the computer still thinks you got the stock 4.0L sitting under there. For a little more power you can spend a few hundred more bucks and get and intake, headers, bored throttle body, electric fan conversion, and an exhaust. That would push you to about 270 hp probably. After that you may need to start worrying about the drivetrain though. And I would deff. suggest going with MORE bomb proof motor mounts for this application. If you would like for information and help just pm me.
This was VERY helpful, thank you!
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Old 02-16-2008, 11:18 AM   #14
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Yea, no problem at all.
Lev, that was my point indeed. You dont have to drop $1500-2000 to build a stroker motor if you know the list of things you'll need.
Now, if you can find yourself a rolled cherokee like I had suggested then you could probably also pull the tranny too for cheap with the motor. That way you could just drop it all in as one big unit and not have to worry about the costly adaptions youd have to do to mate the new 4.0L and your current tranny. But the fact is, you could probably pull a 4.0L from a Jeep that has the same tranny in it as you do now. Then it would bolt right up. I didnt catch what tranny you said you have but I will read back through and try to see if I can find you what years came with a 4.0L and your trans. Then you wouldnt even need to worry about it. Also, the cost of the 4.0 computer and wiring harness is cheap if you look on ebay. There are deals everywhere, you just have to know where to look for them. But I'll help you in any way I can on this.
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Old 02-16-2008, 11:27 AM   #15
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Check this auction out. Its only got a few hours left on it but the guy said he wants to get rid of everything. Including the coputer and harness too. Its only at 99 cents and reserve isnt met but Im sure you could talk to him after the auction and work out a deal. Its only got 123K on it too which isnt bad at all. It jsut sucked up some water. He flushed it and put new oil and says it still runs so its perfect for a rebuild.
http://cgi.ebay.com/ebaymotors/Jeep-...spagenameZWDVW
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Old 02-16-2008, 12:02 PM   #16
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I can't drive to Vermont, and it has to be a 99 or newer motor because California is retarded.
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Old 02-16-2008, 12:28 PM   #17
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Ah, I see. Wasnt aware of that rule. I just found that after a few seconds of searching so I will keep looking. Im sure it wont be hard to find one in Cali.
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Old 02-16-2008, 02:52 PM   #18
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Thanks for keepin an eye out for me
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Old 01-31-2010, 08:54 PM   #19
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I can't drive to Vermont, and it has to be a 99 or newer motor because California is retarded.
Have to 2nd you on that one. I am military and they would not let me on base untill i got a California smog because i have Nevada plates. Am new to the area any good trails out here close to travis AFB?
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Old 01-31-2010, 09:18 PM   #20
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