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Old 07-11-2019, 09:39 PM
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Question XJ Everything into YJ

I found a lot of threads asking about putting Cherokee parts in a YJ, and it sounds like a lot of the problems come from incompatibility between the motor, the transmission, and the T-case.
I have effectively a donor 2001 Cherokee with a recently rebuilt I-6 motor, AW-4, and NP231. They're in much better condition than my I-4, AX-5, and NP231 in my YJ. If I wanted to put the whole powertrain (effectively) into my YJ, it seems like that would take a lot of the extra cost and headache out of it. What do you guys think? If I have the parts, and what I have right now is not so great, do you think it's worth it? Are there any major concerns? I'm really excited for the opportunity, and the project, but I don't want to get too deep over my head.

Thanks!

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Old 07-11-2019, 10:08 PM   #2
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I dont know how you would get the OBD2 computer to play with the YJ gauges is my first thought.



AW4 is a great transmission though but the clocking would need to be changed to fit in the YJ.

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Old 07-11-2019, 10:20 PM   #3
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Motor mounts are different. Changing them requires welding new mounts.
You may need to change some of the XJ engine accessory brackets for YJ brackets.
You'd need to figure out some way to shift the AW4. (YJ column shift or aftermarket floor shift).
Other posters can probably add to the list.

Good Luck, L.M.
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Old 07-12-2019, 04:16 AM   #4
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Save yourself the cost (it adds up quick) and aggravation of doing that swap. Either sell the YJ and buy a 6 cyl or sell the Cherokee and rebuild the 4 banger.
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'94 YJ 5sp 5.13, Super 35, HP30 w/Aussie, sitting on 33's, RE chromo drag link, 9500 Lb winch, 3" lift, 4x4 Posi Lock, it's a resto-mod in progress.
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Old 07-12-2019, 12:28 PM   #5
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THE problem is that hundreds of people read over and over that it doesn't work the way the want it to and a large percent think their situation is an exception....
Swapping a 2.5 to a 4.0 is and always will be a huge job...
Swapping in a vortec 5.7 for example is JUST barely more of a project.
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Old 07-12-2019, 05:29 PM
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Thanks, guys! Sounds like it's going to be a pain. I definitely expected that. I wasn't sure if having the Big Three from the same donor would make it less painful. I couldn't find a whole lot of advice in past posts that was more than "sell it and buy a 4.0, it's going to suck". I might still take it on, since it'll be a challenge. Or I'll clean up the XJ parts and sell them, and reinvest.
If I go that route (this is a pretty rookie question, because I'm a rookie), how much should I expect to pay (ish) for a 2.5 rebuild, or a new 2.5 and AX-15? All the prices I see online are up in the thousands, but I can't find anything that's not brand new, or refurbished by some designer off-road company.
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Old 07-12-2019, 06:11 PM   #7
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Quote:
Originally Posted by SpiritOf86 View Post
If I go that route (this is a pretty rookie question, because I'm a rookie), how much should I expect to pay (ish) for a 2.5 rebuild, or a new 2.5 and AX-15? All the prices I see online are up in the thousands, but I can't find anything that's not brand new, or refurbished by some designer off-road company.
From a rebuilder complete long block with 1-7 year (depending on the vendor) warranty that will run around $1200-3000 a junkyard AX15 where I live will be in the $500 range. Gets some quotes locally before you pull the trigger. Here a few links for long blocks that I've been looking at.


https://www.shop.505performance.com/...?categoryId=40

https://gearheadengines.com/engines/.../?partid=61488

https://www.sandjengines.com/search/...EEP-Wrangler--

https://fraserengineco.com/thank-you/
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'94 YJ 5sp 5.13, Super 35, HP30 w/Aussie, sitting on 33's, RE chromo drag link, 9500 Lb winch, 3" lift, 4x4 Posi Lock, it's a resto-mod in progress.
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Old 07-13-2019, 06:31 PM
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Wow, that's quite a bit. I'm not new to mechanic-ing, but I'm relatively new to Jeeping, so I don't have a good feel for that stuff yet. Part of the problem is that I'm in Upstate NY, and junkyards are like unicorns up here. If I want a decent pick & pull I have to drive out of state. I thought about selling the XJ stuff, but there's just not a market for it up here, apparently. I don't think I know how to buy and sell parts.
Alright, I know you guys are being firm but gentle, but part of the reason I'm taking this on is because I love challenging projects. So, while I understand it's a terrible idea, I'm less in the "buy a new motor" budget range, and more in the "get a drill and make it work" range. Understanding that, I'm looking at:

- changing the motor mounts

- changing the transmission mount

- coolant lines for the AW-4

- wiring harness change/modification

- ECM swap

- make exhaust work

Anything else anyone can think of that I'll have to get through? If you give me a hand and this works out, I promise I'll pay you back by taking a lot of notes and pictures.

Thanks!
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Old 07-13-2019, 07:00 PM   #9
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You'll need a manual with the YJ schematics and another manual with the XJ schematics.
Factory Service Manuals are better than aftermarket manuals.
Many of the YJ wires and the XJ wires are the same color for any particular function but the pin outs (wire locations within any plug) could be different.

Another handy tidbit of advice, don't get rid of the Cherokee or anything on it until you have the YJ on the road and running properly.

Once you're into the project, you can ask questions about whatever issue you're facing.
Many posters here have done the same swap so hopefully you'll get quality answers to your questions.

Good Luck, L.M.
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.................................................. ........................
1987 YJ-4.2L-Standard Shift- Re-manufactured Carter Carb-2" body Lift-31X10.5X15 BFG KOs-190K Miles No back seat.
HEI distributor with computer and all related relays and wiring removed.
12K Badlands winch with dual batteries.
Warn front bumper. Matching imitation Warn bumper on the rear.
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Old 07-13-2019, 10:20 PM
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Alright, awesome. I appreciate the support. I'll track down some service manuals.
Thanks!
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Old 07-17-2019, 02:09 AM   #11
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Just mentioning, an XJ transfer case is clocked lower than a YJ's.
The YJ skid plate may not even fit without modification because of it.
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Old 07-21-2019, 11:57 AM
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Thanks for the heads up. I didn't think of that. I have a pair of skid plate drop spacers that I'll throw on if I need to.
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Old 07-21-2019, 06:24 PM   #13
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Thanks for the heads up. I didn't think of that. I have a pair of skid plate drop spacers that I'll throw on if I need to.



That will not work the transmission tail housing will need to be drilled. The only way to "fix" the clocking with drop brackets would be to space the skid down and the transmission mount up and that is just a very stupid thing to do. Re-drill the holes or dont even bother you are way in over your head.
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Old 07-21-2019, 07:04 PM   #14
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I'm deep into a swap from a (1989) 4.2 to a (1995) 4.0. Its much more involved than I anticipated, but that's mostly my fault. I decided I didn't want to hodgepodge the old Renix wiring to make the OBD1 work so I bought an in dash harness. The 95 in dash looks the exact same as the 89, but it is completely different. So, out with the old gauge bezel and in with the new... not bad for $50. Out with the old tach and speedo cluster and in with the new... not bad for $95. Oh wait, the rear harness doesn't play with the new dash harness. My point is, its always something and that's YJ to YJ. YJ to XJ is going to be more difficult.

Is it doable? Absolutely. Is it cost effective? Probably not. I would think long and hard about the costs before I pulled the trigger. By the time you're done you could probably have a pretty nice engine built and transmission replaced for cheaper. I'm deep into mine and I already had a ton of money spent on lift and everything else (practically a full restore) before I decided to swap the engine. The good thing is by the time I'm done there won't be a part on the jeep that I won't know, intimately, before its all said and done.

If you want a project you won't be disappointed. Just don't be firm on a dollar amount or time frame. I'm hoping to have mine on the road by Winter and I stopped paying attention to the costs.
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Old 07-26-2019, 10:38 PM
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@Gotlift -- Ouch. Price/budget is definitely a limiting thing for me. I don't really have much experience selling parts in the last 10 years, and it seems like everything's changed quite a bit. Or Craigslist just sucks where I live. So I'm a little anxious about trying to sell the motor and stuff. I'm getting the feeling I should just listen to everyone above and sell it. @agalloch07 -- Thanks for the heads up. I understand now.

Edit -- fixed a username
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Old 12-11-2019, 11:39 AM   #16
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I've done this. Dropped a 1995 Cherokee 4.0 into a 1992 YJ with an Ax15 and a Dana 300 and a 1984 Dana 44 rear.
I used all the wiring form the Yj and modified the ends from the Cherokee harness or just swapped out sensors altogether and used the YJ computer and it all worked great.
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Old 12-11-2019, 12:14 PM   #17
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I've done this. Dropped a 1995 Cherokee 4.0 into a 1992 YJ with an Ax15 and a Dana 300 and a 1984 Dana 44 rear.
I used all the wiring form the Yj and modified the ends from the Cherokee harness or just swapped out sensors altogether and used the YJ computer and it all worked great.



95,92 are compatible years 2001 does not have a provision in the head for the gauge temp sender. It also has the OPDA and coil packs for each plug and a cylinder head known for cracking. And the YJ computer/cps probbaly wont work with the 2001.
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Old 12-21-2019, 07:00 PM   #18
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And I think, then you will need new Drive Shafts also, $$.

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