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Old 01-17-2017, 09:54 PM   #1
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Drive train swap options...

So over the last 2 years that ive had my yj. it has become very clear to me that the 2.5l i4 is somehwat underpowered and frankly not well... ive been kicking around the ideas of a drivetrain swap. to possibly a 4.0, 5.2 5.3, 5.7 even a 4.3. or an om617 if i could find one cheap enough...

i believe ive gotten it narrowed down to the following options and ideas of where to proceed with the next step in the life and evolution of my yj.

1st - a rebuild/refresh and upgrade the 2.5 better head, cam, intake and exhaust

2nd - 4.3 swap either efi or carb.

3rd - 5.2 swap aslo efi or carb.

of the options mentioned above a rebuild of the 2.5 would be nice to get it healthy again and make her scream for another 180k+. ive got both a 4.3 and 5.2 at my disposal to play with. i recently got my hands on a free 98 grand cherokee w/ a 5.2/auto as a salvage vehicle. motor turns over but no keys or steering column to try to drive it to see what the real health of the motor would be... the 4.3 will need a rebuild and a deep cleaning! but with a conversion bellhouse from novak it would bolt up to the ax15 that ive collected for the upcoming build. the 5.2 would bolt up with the bellhouse from anything from a 3.9 to 5.9 and they are available in salvage yards and online. just takes some more cash to find one lol.

the other issue im having is that there arent alot of wiring write ups for the 5.2 swaps. like what all can and could be cut out of the stock v8 harness that wont be used anymore that wont make the computer go crazy and not function properly...

thats more or less the reason im leaning towards a carb set up myself. had a little experience with them and it can be made to work relatively simply.

right now im really leaning hard to the 5.2 ax15 swap with a carb set up.

all i would need is motor mounts, carb intake, hei ignition set up, v8 dakota ax15 bellhouse, fuel pressure regulator. then id need to get some new drive shafts made up to lengthen the front and probably shorten the rear shaft. gonna be swapping in a 8.8 and stretch it 2''. if the money is there ill see if i can do a sye for the 231j. ill have to beef up the d30 with better shafts and a small lunch box. but all in all thats about everything i can think of currently.

any input, opinion and direction is welcome.

i think im just floundering a bit at the moment. its just a bit overwhelming. this will be the 1st official drive train swap ive ever attempted. ive pulled and replaced many an motor, transmission and axle. but never built a rig from the ground up...
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Old 01-18-2017, 08:20 PM   #2
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I fully understand the carb vs. EFI considerations for wiring etc. but from what I have read the real determining factor should be what your plans are - mild off-road and on-highway carburetor is easier; but heavy off-road with rough/steep terrain needs EFI to get over the issues associated with carburetors in those conditions. If you have the complete vehicle the 5.2 EFI is coming from the wiring harness should not be too bad (at least in theory). Use everything from the engine to the computer from the donor vehicle and by comparing wiring diagrams between the two vehicles you can determine which wires from the YJ need to interface to provide power, ground, gauges, etc.

I am not familiar with the 5.2 but in my case the SBC location as close to the firewall as I dared worked out very well for drive shaft lengths.

Projects like this can be daunting but keep doing your research and asking questions here until your ready to pull the trigger. Once you do start just keep working at it as there will always be unexpected "opportunities" that arise but none that you can not overcome.

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Old 01-19-2017, 06:46 AM   #3
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Going to a carb would be going backwards big time, in many ways. Depending on your local laws and inspection requirements, it may cause emission test failure.

The 5.2 wiring can be methodically figured out. It will be time-consuming, but very possible.

I don't see the attraction of the 4.3L swap at all. If you are going to do that, then just drop in a Jeep 4.0L/AX15. The wiring for the Jeep 4.0L swap is very easy. If that's a big consideration for you, then go 4.0L.
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Old 01-20-2017, 01:04 PM   #4
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I fully understand the carb vs. EFI considerations for wiring etc. but from what I have read the real determining factor should be what your plans are - mild off-road and on-highway carburetor is easier; but heavy off-road with rough/steep terrain needs EFI to get over the issues associated with carburetors in those conditions. If you have the complete vehicle the 5.2 EFI is coming from the wiring harness should not be too bad (at least in theory). Use everything from the engine to the computer from the donor vehicle and by comparing wiring diagrams between the two vehicles you can determine which wires from the YJ need to interface to provide power, ground, gauges, etc.

I am not familiar with the 5.2 but in my case the SBC location as close to the firewall as I dared worked out very well for drive shaft lengths.

Projects like this can be daunting but keep doing your research and asking questions here until your ready to pull the trigger. Once you do start just keep working at it as there will always be unexpected "opportunities" that arise but none that you can not overcome.

i havent done any hardcore wheeling in my yj but i do drive my jeep often on the road/highway and do alot of trails and a bit of mud and a little bit of rock every now and again. i think that ill be going to the route of the 5.2. hopefully i can get the wiring figured out. efi is appealing but the simplicity of carb is sounding quite nice tho... hoping that this swap will be quick and straightforward...
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Old 01-21-2017, 12:26 PM   #5
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I had a 70 cj 5 before I went to my 93 Wrangler. Had problems with the floats in the carburetor. I like the fuel injection because of its simplicity. I am located in Northwestern Calif and the quality of the local mechanics aren't that good. That's why I replaced the cj with a 93 4.0 wrangler.
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Old 01-21-2017, 11:59 PM   #6
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ive been putting out some feelers and trying to gather more info locally about the swap and there always seems to be some interest from the local wheelers in helping me get this project going. but everyone around here seems to have gone the 5.3 ls or the 5.7 vortec way instead of the 5.2 or 5.9. or even a 3.9 cummins... woot 4bt!! boom. ya thats not happening lol. way to expensive of a swap!
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Old 01-22-2017, 01:50 PM   #7
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Originally Posted by rusty_wangler91 View Post
ive been putting out some feelers and trying to gather more info locally about the swap and there always seems to be some interest from the local wheelers in helping me get this project going. but everyone around here seems to have gone the 5.3 ls or the 5.7 vortec way instead of the 5.2 or 5.9. or even a 3.9 cummins... woot 4bt!! boom. ya thats not happening lol. way to expensive of a swap!
most likely do to the fact that places like holley have stand alone wiring/computer kits for the GM motors that help get the motors up and running quickly
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Old 01-23-2017, 09:24 PM   #8
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most likely do to the fact that places like holley have stand alone wiring/computer kits for the GM motors that help get the motors up and running quickly
i sure wish i had the cash for an ls swap! that be a fantastic swap! im just trying to make my jeep the best it can be within my means! definitely harder than i thought it would be... but itll end up where i want it to be!
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Old 01-25-2017, 09:33 AM   #9
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Can't beat fuel injection, I think it is worth the hassle. Carbs have issues on hills, the floats don't do so well at certain angles and will cause the engine to load up. Very bumpy roads can do the same. Good wiring diagrams and lots of patience is all it takes to to get the FI system to work.
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Old 01-29-2017, 10:03 PM   #10
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I love my 4.3 conversion...I replaced my 4.2 with it....with a complete Chevy running gear...try getting 20 mpg outta any 4.0 or 4.2.
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Old 01-30-2017, 01:20 PM   #11
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I love my 4.3 conversion...I replaced my 4.2 with it....with a complete Chevy running gear...try getting 20 mpg outta any 4.0 or 4.2.
I love mine also. 2000 4.3 vortec 4l60E automatic. Kept the fuel injection and all of the factory Jeep gauges work. I would of gone V8 but the 4x4 S10's are so much cheaper than the full size V8 trucks. I don't get 20mpg but I hated the 4 banger.
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Old 01-31-2017, 04:13 PM   #12
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Mines an 87, I have 308 gears
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Old 02-01-2017, 10:27 AM   #13
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Can't beat fuel injection, I think it is worth the hassle. Carbs have issues on hills, the floats don't do so well at certain angles and will cause the engine to load up. Very bumpy roads can do the same. Good wiring diagrams and lots of patience is all it takes to to get the FI system to work.
im still up in the air about either efi or carb. found more info on my the carb swap and still not so much about taking the harness from the full wiring harness to a standalone setup.

took some digging but the turns out the magnum motors will accept the older style distributors. even had it confirmed on a few forums once i had the right search parameters entered... i swear mopar people dont like to give up the secrets of their cars and how it all fits together and whats swappable and such which is almost opposite of the jeep, ford and chevy guys at least from what ive seen...
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Old 02-08-2017, 03:02 AM   #14
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I don't see the attraction of the 4.3L swap at all. If you are going to do that, then just drop in a Jeep 4.0L/AX15. The wiring for the Jeep 4.0L swap is very easy. If that's a big consideration for you, then go 4.0L.
Because honestly, as much as I love the Jeep Straight 6, it really doesn't match a 4.3 The 4.3 for the last 20 years, makes 20 pounds more torque, it weighs almost 100 pounds less, and it gets significantly better fuel economy. Parts for it are plentiful and dirt cheap and if you feel so inclined it has a healthy after market and responds to performance parts like, well, a small block chevy.

It's also a 300K mile engine easily. But to be fair, the AMC straight six was designed in 1963, 15 years before the 90º V6s were. I long considered a 4.3 swap for mine. I also happen to have a 5.9 Magnum in the garage, and honestly, there just isn't a lot of support for putting mopars in Jeeps. It's utterly doable if you're the fabricating type, but there just isn't an elegant solution. You can pick up the phone and order just about everything to literally bolt a chevy into a YJ without needing to fire up a welder once.

It all depends on how handy you are feeling. If you are trying to figure out the wiring for a non-native EFI set up, you might find that's enough on your plate rather than trying to figure out if the engine is straight and sitting where its supposed to be. The Chevy stuff has been figured out the death and is over-the-counter at this point. As for putting a 4.0 in it, it's not a native swap because the engine mounts on the chassis of the 2.5 are in the wrong spot. So if you're going to be fabricobbling, you might as well make it worth your while. The transmission behind a 2.5 won't last very long behind a 4.0 anyways, so that would have to go.

For what its worth, there is everything you would want to know on the Novak Conversion website. They have documented just about every feasible (Because there are some infeasible options as well.. 20B Wankel power, anyone?) engine/tranny/combo swap you could want.
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Old 02-10-2017, 12:47 AM   #15
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Because honestly, as much as I love the Jeep Straight 6, it really doesn't match a 4.3 The 4.3 for the last 20 years, makes 20 pounds more torque, it weighs almost 100 pounds less, and it gets significantly better fuel economy. Parts for it are plentiful and dirt cheap and if you feel so inclined it has a healthy after market and responds to performance parts like, well, a small block chevy.

It's also a 300K mile engine easily. But to be fair, the AMC straight six was designed in 1963, 15 years before the 90º V6s were. I long considered a 4.3 swap for mine. I also happen to have a 5.9 Magnum in the garage, and honestly, there just isn't a lot of support for putting mopars in Jeeps. It's utterly doable if you're the fabricating type, but there just isn't an elegant solution. You can pick up the phone and order just about everything to literally bolt a chevy into a YJ without needing to fire up a welder once.

It all depends on how handy you are feeling. If you are trying to figure out the wiring for a non-native EFI set up, you might find that's enough on your plate rather than trying to figure out if the engine is straight and sitting where its supposed to be. The Chevy stuff has been figured out the death and is over-the-counter at this point. As for putting a 4.0 in it, it's not a native swap because the engine mounts on the chassis of the 2.5 are in the wrong spot. So if you're going to be fabricobbling, you might as well make it worth your while. The transmission behind a 2.5 won't last very long behind a 4.0 anyways, so that would have to go.

For what its worth, there is everything you would want to know on the Novak Conversion website. They have documented just about every feasible (Because there are some infeasible options as well.. 20B Wankel power, anyone?) engine/tranny/combo swap you could want.
ive really considered a 4.0 swap since i have a complete zj drivetrain at my disposal to cut apart and use as much of as i need to. but since the 5.2 was free and v8 always worth it in the end with the gobs of tq and oh that v8 rumble! i got to experience a 350 swapped yj a few months back during my looking through craigslist for new possible projects! and oh wow that was fun! if it had been a manual id be working on it as we speak but sadly it was an auto and a very unhappy turbo350 to boot... but oh wow that was fun.

ah the lengths we will go to to keep our projects happy and healthy!

im sure it is a bit on the blasphemy side of things. but i even considered getting the 2.5l refreshed and cam upgrade. swapping the ax15 with the 2.5 dakota conversion bellhousing and then saving up more and more money to get the d30 and 8.8 regeared to 4.88's and then enjoying it for what its worth. with the little bit of power that the 4banger has and a beefed up drive train that could definitely take some abuse and laugh about it! still kicking it around here and there... oh the money i could save... ugh. lol decisions decisions decisions lol!
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Old 02-10-2017, 12:48 AM   #16
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well i think ive pretty much set on the 5.2 swap. lol. ive found the correct set of conversion motor mounts from advance adapters for a reasonable price. ill be putting an ax15 behind the 5.2 in stock form that should hold up just fine. ive been doing more info hunting on the swap. and ive found that there is a company up in oregon that will rework the wiring harness and make it 100% plug and play and a perfect mix of yj and v8 zj harness. but its $800 for their services... so theres plusses and minuses. lol. its either simple carb or custom efi. again great stuff. i found a magnum swap guide over on pirate4x4.com that outlines the placements and sorta how everything fits together and mates somewhat successfully.

my plans currently are
98 zj 5.2 v8, 94 zj ax15 w/ 23spline 231j, dakota 5.2 to ax15 bellhouse. speedway conversion magnum carb intake w/ edelbrok 600 cmf carb. gonna reuse the stock zj headers and y pipe.

and all the fun that follows a swap like this!
clocked flat 231j. flat skid plate .25 plate. barnes4x4 tubular trans crossmember. custom drive shafts using the stock zj drive shafts shortened or lengthened to fit just right. might still go with a sye for the 231j depending on how it all looks when it gets put together. 8.8 rearend stretched 2-3". tj rear corner armor to match the stretch and gas fill relocation. hybrid 4.5" maxima led tail lights. all needed rust repair in tub under b-pillar. coat inside of the tub in bedliner to seal the repairs and make it pretty again!

this is the list im going with lol. im probably going to be doing this in phases lol. just to try to keep the down time a minimum and the usefulness of the jeep to a maximum! gotta be able to enjoy those doorless summer days!
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Old 02-10-2017, 11:45 AM   #17
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well i think ive pretty much set on the 5.2 swap. lol. ive found the correct set of conversion motor mounts from advance adapters for a reasonable price. ill be putting an ax15 behind the 5.2 in stock form that should hold up just fine. ive been doing more info hunting on the swap. and ive found that there is a company up in oregon that will rework the wiring harness and make it 100% plug and play and a perfect mix of yj and v8 zj harness. but its $800 for their services... so theres plusses and minuses. lol. its either simple carb or custom efi. again great stuff. i found a magnum swap guide over on pirate4x4.com that outlines the placements and sorta how everything fits together and mates somewhat successfully.

my plans currently are
98 zj 5.2 v8, 94 zj ax15 w/ 23spline 231j, dakota 5.2 to ax15 bellhouse. speedway conversion magnum carb intake w/ edelbrok 600 cmf carb. gonna reuse the stock zj headers and y pipe.

and all the fun that follows a swap like this!
clocked flat 231j. flat skid plate .25 plate. barnes4x4 tubular trans crossmember. custom drive shafts using the stock zj drive shafts shortened or lengthened to fit just right. might still go with a sye for the 231j depending on how it all looks when it gets put together. 8.8 rearend stretched 2-3". tj rear corner armor to match the stretch and gas fill relocation. hybrid 4.5" maxima led tail lights. all needed rust repair in tub under b-pillar. coat inside of the tub in bedliner to seal the repairs and make it pretty again!

this is the list im going with lol. im probably going to be doing this in phases lol. just to try to keep the down time a minimum and the usefulness of the jeep to a maximum! gotta be able to enjoy those doorless summer days!
I wouldn't say it's blasphemy to rebuild the stock engine. That's the beauty of jeeps, is you can do them pretty much anyway you want. . As for going Carb, as long as it isn't a legal issue where you are, that should be easy enough. If you had a bit more engine I'd say give one of those Holley Low Rider carbs a try (Only available in 670 cfm). They're designed for cars with hydraulics, and Holley says they work on a 40º Nose up and 30º left/right tilt. Wonder if they can be jetted down...
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Old 02-10-2017, 11:49 PM   #18
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I wouldn't say it's blasphemy to rebuild the stock engine. That's the beauty of jeeps, is you can do them pretty much anyway you want. . As for going Carb, as long as it isn't a legal issue where you are, that should be easy enough. If you had a bit more engine I'd say give one of those Holley Low Rider carbs a try (Only available in 670 cfm). They're designed for cars with hydraulics, and Holley says they work on a 40º Nose up and 30º left/right tilt. Wonder if they can be jetted down...
honestly thats one of the things that drew me to jeeps in the first place is just how customizable they can be. they tend to take on the characteristics of their owners throughout their life up until they cant be repaired or fixed in the end...

ive recently joined a new local jeep club and im going to try to get some feed back from local guys who have non stock drivetrains in their rigs. from what ive read about missouri's laws regarding drivetrain swaps and such is it cant be an engine older then the model year of the body and my jeep is old enough that it doesnt get the sniffer just a visual inspection. a cat is required but is rarely enforced at many of the inspection shops...
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Old 02-14-2017, 09:08 PM   #19
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I have a 93 Renegade (YJ) that I rebuilt the top end a few months ago. Yesterday she took on water in the block. With 350k+ I think it is time for a new block. No guarantees with my 4.0 HO even if tried to fix. My Jeep is my daily ride and I love the inline six but lack the funds to replace. However, I do have immediate access to a 4.3. Trouble is all my experience is with Jeeps and know nothing about the Chevy 262. Currently I have the AX15 tranny and stock Dana 35. Any info about mods and adapters etc.. and even personal experiences/opinions(educated ones) would be extremely helpful. Thanx
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Old 02-19-2017, 09:45 AM   #20
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I have a 93 Renegade (YJ) that I rebuilt the top end a few months ago. Yesterday she took on water in the block. With 350k+ I think it is time for a new block. No guarantees with my 4.0 HO even if tried to fix. My Jeep is my daily ride and I love the inline six but lack the funds to replace. However, I do have immediate access to a 4.3. Trouble is all my experience is with Jeeps and know nothing about the Chevy 262. Currently I have the AX15 tranny and stock Dana 35. Any info about mods and adapters etc.. and even personal experiences/opinions(educated ones) would be extremely helpful. Thanx
honestly, itd be cheaper to find another lower mileage 4.0 to swap in and get ya back on the road! any swap isnt going to be cheap in any way shape or form... 4.3 chevy swap out of an s10 is reasonable. but you're still looking at around 2k for it all said and done and thats if you do all the work, wiring and find a reliable donor for cheap and reuse as much as possible...

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