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Old 04-03-2013, 11:40 PM   #1
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My 5.2L Magnum build

Here we goo! Fooled around one more time the other night with my Jeep as is:



Even left the ground once (or 5 times):



I think I will name this project after the great Emmett 'Doc' Brown's famous words.

"Roads? Where we're going we don't need roads!"

Here's the plans:

-Magnum 5.2L V8
-AX15 5 speed Transmission
-NP231J Transfercase with SYE
-Dana 44 front axle, locked
-Ford 8.8 rear axle, locked (suggestions on lockers?)
-OBA system
-Metalcloak Overline fenders with 6" flare
-Metalcloak rock sliders
-Some front bumper (have yet to decide)
-Rear bumper with swingout tire carrier
-Drop down tailgate
-Winch
-35" tires, Jeep chrome wheels
-4" suspension lift/1" boomerang shackles
-Monstalined tub (inside and out)
-Family rollbar conversion
-New soft top, and a hard top
-Audio system (we will figure this one out when we get there)
-LED headlights, tail lights, reverse lights, turn signals, marker lights, dash lights, dome lights
-Baja Designs 51" OnX LED light bar
-Baja Designs Squadron LED Driving lights
-Baja Designs Squadron LED Spot lights
-SuperBrightLED's Mini 10 and 20w LED lamps behind, in front, and underneath

Uhh I think that's it for now... Still trying to locate a Jeep Grand Cherokee with said V8. Hoping for one with OBD2..

Still bummed every bolt of the way though...

Sofar here is where we are at with the deconstruction. Tiny little engine.



This is my concept.


(Not sure who's Jeep this is but I hope you don't mind me using it for mock up purposes!)

Bear with me. I'm a bit slow with things, especially since this is my pride and joy. Colors are going to be courtesy of MONSTALINER Light Quartz Gray and Predator Green. Chrome grill insert, Chrome wheels, that's it for the shiny.

Tomorrow comes the wiring harness and next week I will be yanking the engine/tranny/t-case out. In the meantime, does anyone need some 2.5L parts that is not the wiring harness/sensors/misc 2.5L injection bits?

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Old 04-04-2013, 01:58 AM   #2
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Dude, I can't believe you are tossing the 4banger. Good luck with the build man. What made you decide to swap to 5.2?

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Yep.
She's my 4 banger.
She's great when she gets down in low range, hard to control when she gets going, and always in need of my money. But she's a jeep and that's why I love her.
Plus, she has nice headlights..
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Old 04-04-2013, 03:10 AM   #3
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Quote:
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-Magnum 5.2L V8
-AX15 5 speed Transmission
-NP231J Transfercase with SYE
Im on the fence between the AX15 and a NV3550
I have both and ill probably go with the 3550, and I was defiantly going with the 5.2L, but when I got the 3550 it came with a bell for a Hemi or 4.7L, so...

FYI: the AX15 and the NV3550 have the same bolt pattern for the bellhousing...
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'93 Black YJ, 4.0L AX15 - UNDER CONSTRUCTION!
http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-04-2013, 11:38 AM   #4
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So you are saying I should probably hold out for a 3550 over an AX15? Seems like the AX15 is more readily sourced.
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Old 04-04-2013, 03:04 PM   #5
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Got the engine harness and computer out, as well as most of the dash and interior.



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Old 04-04-2013, 05:18 PM   #6
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What's this??? The King of 4 bangers putting in a V8? I knew you would see the light eventually!
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Old 04-04-2013, 05:41 PM   #7
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Nothing wrong with the 2.5L. It did everything I asked of it. Only reason I am going to a V8 is I don't want to pay over a grand to have mine rebuilt, or more for a reman unit. Would rather stuff something bigger in, and build it up as well.
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Old 04-04-2013, 06:51 PM   #8
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You gave me a lot if crap when I was doing my conversion. Just wanted to give a little back! ;-)

You are going to LOVE your jeep now! No more getting passed by semi-trucks going uphill. I'm getting 18-20 mpg too!

Good luck! Let me know if you need any pointers. Been there, done that!

PS- might need to grab the gas pedal and control box. I believe they are drive by wire, not cable operated like your stock set up.
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Old 04-04-2013, 10:36 PM   #9
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I'm getting a donor GC, so whatever the engine needs to operate I will pull off of it

My yard is slowly turning into a junkyard. As of today, here is where we are at:











Most of my extra parts are for sale, fenders, carpet, dash, etc. I won't ship the larger items though. If anyone is interested...
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Old 04-05-2013, 02:17 AM   #10
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So you are saying I should probably hold out for a 3550 over an AX15? Seems like the AX15 is more readily sourced.
You can swap back and forth, so use what you have....

the NV is like .2" longer
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http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-05-2013, 11:23 AM   #11
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I have an Ax5 so that's not quite going to work

In the meantime I've found the gauges I want to use:

Intellitronix Corp.

I think I will go with a custom dash layout rather than use the premade gauges.
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Old 04-06-2013, 10:35 PM   #12
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Got the engine basically stripped, just gotta pull the water pump and it's bare:

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Old 04-09-2013, 12:13 AM   #13
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The almighty 2.5L is out!!!



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Old 04-09-2013, 12:56 AM   #14
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What year is your jeep? Your factory gauges will work with the 5.2. Only one not onboard with my 87 is the tach. The later ones work fine.

Just as others have said, you will love it. Fits so nice. Everyone says mine looks factory. Just sits in there so naturally. Use an airbox of a ram, flip it sideways to clear the hood. You will need a computer from a truck or van, the gc's have security system that wont allow it to run without the security hooked up.

Got any questions pm me. I used a 93 donor, obd1. Just got mine done a month ago. Have wheeled it a few times.
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Old 04-09-2013, 01:11 AM   #15
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Is there any reason you stripped the engine before you removed it? I normally leave as much as I can still hooked to it when I pull a motor....
Just remove the wire harness, fuel, and cooling system, clutch & all linkages, drive-shafts, cables, MAYBE remove the t-case, and pull the whole thing out complete.
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'93 Black YJ, 4.0L AX15 - UNDER CONSTRUCTION!
http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-09-2013, 11:48 AM   #16
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Quote:
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What year is your jeep? Your factory gauges will work with the 5.2. Only one not onboard with my 87 is the tach. The later ones work fine.

Just as others have said, you will love it. Fits so nice. Everyone says mine looks factory. Just sits in there so naturally. Use an airbox of a ram, flip it sideways to clear the hood. You will need a computer from a truck or van, the gc's have security system that wont allow it to run without the security hooked up.

Got any questions pm me. I used a 93 donor, obd1. Just got mine done a month ago. Have wheeled it a few times.
I know the gauges will probably work, but they're ugly and don't fit the theme I am after. They're junk to me.

Quote:
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Is there any reason you stripped the engine before you removed it? I normally leave as much as I can still hooked to it when I pull a motor....
Just remove the wire harness, fuel, and cooling system, clutch & all linkages, drive-shafts, cables, MAYBE remove the t-case, and pull the whole thing out complete.
Less weight on the crane. I pulled the engine/tranny/tcase as one.
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Old 04-09-2013, 12:03 PM   #17
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Ahh, i went with function. And they function. Mines no beauty queen.
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Old 04-09-2013, 03:24 PM   #18
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Yeah i'm kinda after this green theme. The stock gauges work fine, it's just that I'm after something more modern and green:

Intellitronix Corp.

I've managed to locate a Grand Cherokee but it's a 1993... Still hoping to find the one I'm after in my price range...
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Old 04-09-2013, 03:34 PM   #19
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Rocker Switch Zombie Light Symbol (Blue) : Amazon.com : Automotive

I was going to suggest this with your green theeme, but now that i look at it its more blue,,,
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'93 Black YJ, 4.0L AX15 - UNDER CONSTRUCTION!
http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-09-2013, 08:31 PM   #20
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Plus it says it's blue colored
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Old 04-10-2013, 08:23 PM   #21
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Quote:
Originally Posted by Xpress View Post
Yeah i'm kinda after this green theme. The stock gauges work fine, it's just that I'm after something more modern and green:

Intellitronix Corp.

I've managed to locate a Grand Cherokee but it's a 1993... Still hoping to find the one I'm after in my price range...
I love the digital gauges
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Old 04-10-2013, 09:15 PM   #22
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The search for the right Grand continues...

In the meantime I have dropped the axles out, have a buyer coming to get them friday. Sold my transmission. Got all my other junk I need to sell still. Patience is a virtue I don't have time for!!
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Old 04-13-2013, 12:48 AM   #23
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Here is a swap thread from Pirate, alot will be the same for you:

5.2 Magnum YJ Swap - Pirate4x4.Com : 4x4 and Off-Road Forum
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'93 Black YJ, 4.0L AX15 - UNDER CONSTRUCTION!
http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-13-2013, 02:25 AM   #24
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Pretty good read there. Hoping I don't have to source a lot of parts, since i'm using a donor vehicle.
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Old 04-13-2013, 11:58 PM   #25
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Are you going to run an automatic or 5 speed? Theres a few parts that will need tobe sourced from other that a gc donor, depending on trans of course. Exhaust manifolds, air box, clutch, etc.
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Old 04-14-2013, 11:25 PM   #26
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Like me, you will have to find a Bellhousing for your 5.2L and AX15.

Search Results
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'93 Black YJ, 4.0L AX15 - UNDER CONSTRUCTION!
http://www.wranglerforum.com/f330/2x...ad-490865.html
'04 SV1000s:
http://www.svrider.com/forum/showthread.php?t=280873
Old Jeep that was totaled (and SOLD!):
http://www.wranglerforum.com/f330/2x...ad-101879.html
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Old 04-14-2013, 11:41 PM   #27
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Dakota with a V6. Tons of them around these parts. In fact i used bellhousing, trans and t-case from a dak. Redrilled the trans to clock t-case correctly, otherwise pretty much the same parts. Shifter is different. I just straightened out the bend in mine.
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Old 04-14-2013, 11:54 PM   #28
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Are you going to run an automatic or 5 speed? Theres a few parts that will need tobe sourced from other that a gc donor, depending on trans of course. Exhaust manifolds, air box, clutch, etc.
Trying to find a donor just for the emissions junk. I still gotta source other junk. Then I gotta put it all in my junk

I assume I will need the new bellhousing, what about flywheel? And clutch components? Will be a 5 speed stick.
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Old 04-15-2013, 12:14 AM   #29
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You have to use a flywheel from a 5.2l. While you are getting that get a clutch that matches. I just got one for a 95 dodge 1500 with a 5.2l. Splines are the same as the ax15. You get a 12" clutch. You will need a pilot bearing from the dealer. Its about $20 is all. The ones you get from parts places are just the bearing and you will need the adapter also if your donor is an auto. Dealer only part. I have read some people using the v6 clutch but i wouldnt. Its a bit smaller, and i bet not any cheaper. My flywheel didnt have bolt holes that lined up with the v6 pressure plate anyways.
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Old 04-15-2013, 12:15 AM   #30
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I ended up using an airbox from a 95 ram, a drivers side exhaust mainifold from a durango.

Oh and you need a crank position sensor from a manual trans rig. Grab it from whatever you get the bellhousing off of. The V6 uses the same one.

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