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Project YJ okee

2K views 28 replies 6 participants last post by  BV Jeep 
#1 ·
Well been working on a project for a local couple. They have a really nice 88 YJ but the motor through a rod. So why not throw a motor and transmission out of a Cherokee.

I do have a few questions though. How does the cable shift for the transfer hook up. I'm thinking it would be easier. If you have some pics, that would be great.

Oh and yes the electrical is gonna be a bitch.


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#3 ·
Shifter: This shouldn't be difficult. How about you snap a picture of the parts that you have and we can go from there. Should be the cable and a couple of brackets. Been a while but if I remember right that should be it.

You should be able to lift the electrical off the old engine and put it on the new one and hook it up the same as before. Transmission should be about the same unless one is an auto and the other is manual. If it was the engine that was bad why are you changing the tranny?
 
#4 ·
Going from carburetor to fuel injection. From 4.2 to 4.0. The old motor decided to throw a rod through the block.

Reason I'm asking about the cable shift or is I know a few of you guys have done it. I was able to use the original transfer case due to the speedometer being a mechanical one


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#6 ·
I assume the Cherokee in question is the one you were going to build into a rock crawler. If so you need to steal most of the electrical from the Cherokee and put it in the YJ. Or you can say screw it and pull the manifolds from the old engine and put them on the 4.0. Depends on how much you want the FI and how many headaches you want to put up with to keep it.
 
#7 ·
From what I am reading you need the wiring harness and only tap into 4 wires on the YJ. The shifter for the automatic transmission is just a cable. The transfer case is where I'm asking about the cable shift upgrade.

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#8 ·
Ok, here are pictures of my cable link to the t-case. First picture is the mount that attaches to the body, replacing the bell crank pos. The second picture show the mount that attaches to the t-case. Cable runs between the two mounts connecting the selector lever on the console to the selector lever on the t-case.
 

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#13 ·
Well it's been a while since I posted about this. As you can see there is some progress. Most of the wiring is done, I have the transmission linkage done, and the console mocked up. By the way there is only 17 wires to figure out on the tcm.


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#14 ·
That second pic in post 13 is the way my YJ looked under the hood when I first got it. Though with that it was the way the PO ran the wires for lights, new gauges, ignition etc.
Was my first priority, well second actually. Getting it home before the seller changed his mind on the absurdly low price I paid was first.
 
#15 ·
About 1/3 of those wires run the lights and abs on the old Cherokee. Try are not needed. The fuel pump is is next. Using a pump that fits a Ford Mustang. It's an inline pump.

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#17 ·
The fuel pump is "mounted". It's a E2000 fuel pump from a Ford. Yes a Ford. I have a fuel pressure regulator on the way and a check valve to install to finish the fuel plumbing.


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#18 ·
So been a while but progress is being made. I now have all of the gauges working. Yes that the original YJ gauges mated to the XJ motor. That's means it has 2 oil pressure sending units and 2 temperature sending units. Not to figure out the damn tachometer


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#23 ·
Now it drives. What a project. It's been a very educational project. Now I'm just finishing up a few more things. Mostly on the inside. Hope to have it finished in the next few days.

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#27 ·
Lookin' good Doug! Awesome job!
 
#29 ·
Well after over a year, I finally sent this gem out the door. After it was all said and done, it was a great learning experience for me.

Installing an XJ motor and automatic transmission in a 1988 YJ, it will fit quite nicely. Putting not only an AW4 transmission in a short body rig has its minor issues. You will need a slip yoke eliminator kit and a really short drive shaft. The drive shaft tube us about 1 1/2" long. With a lift kit it requires a transfer case drop and the axle turned up just a bit.

The motor, easy. Just all the damn wiring but a lot of it is not used. You just have to make an XJ motor into a TJ motor. Change the water pump and the fan blades to a TJ motor.

The gauges will work but you have to get creative. Oil pressure sending units, water temp sending units you will need 2 of each. One for the computer and one for the YJ gauge cluster.

The rest will drive you nuts. Transfer case will need a cable shifter. You need to use the original transfer case so the Speedo works. Vacuum systems on the XJ are less than the YJ was so less of a mess.

The last major issue was an issue with it not starting once it was warmed up. I have fretted over this for months, many many months. Well today I finally figured it out. The fuel system has an inline fuel pump and fuel pressure regulator on the frame. It them goes through a fuel check valve and into the fuel rail. Today I put the fuel pressure gauge on the rail and checked it again and it was perfect, still. Well why would it not start? Well once you shut it off the fuel pressure would go up, way up. Luke to 90psi. Too much for the injectors. Removed the fuel check valve and all of a sudden it's back to normal.

Now if you want to so a project like this, go for it. Just remember it takes a lot if time and research.

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