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Old 08-27-2015, 07:46 PM
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99 TJ build and a 5.3 swap

bought a 99 sahara 4.0 and 3 speed auto couple months and now its time to do a few things to it. had a check engine light when i bought it and got all those issues handled. it came with a 2" body lift but i will probably be cutting it down to 1". came with a hard top, bestop sail cloth soft top with tinted windows and the frame and bikini top. ive installed a zone 4" lift with fox shocks, jks adjustable front track bar and jks disconnects. ive got new wheels on order and have to wait for em to be drilled in the tj pattern. i ended up going with a 18x10 moto metal 970 and ill end up with 35's. my main purpose in buying a jeep was to do a v8 swap so a couple days ago i bought a 5.3L and 4L60E complete with wiring harness and pcm. guy said it was a 04 model but i believe its a 99-02 model. i have no truck vin to tell exactly. not sure when ill get around to putting the engine in but hopefully soon!! jeep is a turd with even a small motorcycle trailer behind it. will probably take awhile to get the motor in because the full conversion buying everything from novak comes out to about 5200 so ill buy enough to get the motor/tranny/transfer case in where i dont have to remove it and then just add the rest as i can buy it. eventually i will build my own bumpers from 3/16 aluminum since i have quite a bit around the house.

i have several people interested in my motor and transmission but really not sure what its worth. what would yall think a 4.0 168k miles, has a slight knock for the first few minutes of start up then its gone and a 3 speed auto. transmission shifts flawless.

day i got it home


after the lift


motor pics








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Old 08-27-2015, 08:51 PM   #2
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That is going to be sweet!

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Old 10-20-2015, 08:32 PM
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finally got my wheels and tires in. pays off to shop on craigslist sometimes. ended up buying 3 brand new tires for 25 bucks less than the price of one new one.

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Old 10-21-2015, 12:02 AM   #4
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wow! Looks great, but how does she sound?? Can't wait to see that swap begin. I've got a 2.5L/AX5 combo in my '97 that will have to go. Obviously, a V8 (almost any V8) just has so much more sex appeal than the other options.

Hope ya have time to give a pretty detailed write up during your swap. I realize that adds a whole other PITA factor to a fairly large PITA project. So, you're whole list of parts from Novak required to fit that combo came out to $5200? Do you mind sharing what you paid for the motor/tranny? Would love to see your parts list of Novak gear when it comes time to pull the trigger.

Good luck. Nice looking start to your project!
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Old 10-21-2015, 06:10 PM
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talking about the sound of the tires? if so they are very quiet when they are new, once they get some wear you can hear em just a little bit but not much. ive got the same ones on my tundra and like em so far. i have 1800 in the motor tranny setup. ill take plenty of pics as i go. for some reason tiny pic wont let me upload the quote i got from novak. im sure its in the wrong format.
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Old 11-25-2015, 06:33 PM
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finally got around to starting my rear bumper build. still have a bit left but its a good start. a buddy of mine is going to machine some shackle mounts for me out of aluminum because i cant find em to buy anywhere. i also cant find any swing away carrier mounts for aluminum either so im gonna have to figure that part out. gonna put some flush mount leds for reverse lights as well.





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Old 11-27-2015, 12:47 AM   #7
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I'm pumped for this bumper!! And the rest of the build too!
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Old 01-26-2016, 09:06 PM
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finally got some reverse lights. bought some rigid dually flush flood lights. my bumper angles in a little on both sides so it doesnt let the light shine too far out like i want but it real bright right behind the jeep. think ill end up with some of the rigid SRQ lights and mount in the angles. rigid makes a angled mount where i can make it shine almost straight out. ill be using this jeep for alot of hunting so the more light i have only helps. also i cant find the pieces i need to make a swing out tire carrier, noone seems to make any out of aluminum so i think ill go with comp4x4 dual shear hinge and have a buddy machine out a slleve for inside the bumper and build the rest from steel. havent started on the conversion yet because i wanna get almost all of the parts so my jeep isnt down that long.

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Old 01-27-2016, 05:39 PM   #9
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I have a 5.3ho L33 and 4L65e swapped into my 2005 LJ Rubicon. I used the Novak engine mount, 4L65e trans/NVG241or transfer case adapter and transfer case cable shifter. Most of the other Novak Parts are ridicules in price!
I used 150tune.com for my harness and ecu tune. It was $400 for the harness and ECU! You only have to hook up 5 wires to make it run.
My radiator came from Superior radiator - jeeps and wranglers
The radiator was very nice. $300 for just the radiator or $450 for radiator with shroud and fan. I just got the radiator by itself. I have a Flex-a-light black magic TJ fan turned sideways. It over hangs about 3", and I mounted my trans cooler on the bottom.
Feel free to message me if you have any question.
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Old 01-27-2016, 06:43 PM
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ive messaged back and forth with wayne and when the times comes ill be sending him my harness and pcm, that alone saves quite a bit from novak. im sure when the time comes to start the swap ill have a bunch of questions lol and i may hit you up thanks!!
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Old 01-27-2016, 07:21 PM   #11
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Take the computer off. If the plugs are green and blue, it's 03-06. Red and blue, 99-02. It's either an 02 or up since it doesn't have an EGR. You're going to have to tear apart that whole transmission to change out the tail shaft since it's a 2wd and not a 4wd. You plan on keeping stock gauges? Novak will let you buy an adapter to put the 4l60e with the 231 transfer case that came with your jeep. It's pricey, but if I had to go back I think I would do it.


Edit, never mind. Your guy lied. That engine has an EGR. 99-01 engine.
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Old 01-27-2016, 07:31 PM
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yes i found out after i got home and researched a little more, ive pulled all the egr off and will be deleting it. as far as the transmission i have a buddy that owned a transmission shop for years as a side gig and he is going to build the transmission and replace the shaft for me. yes i plan on using novak for the adapter for my 231 transfer case. as of right now i dont plan on running the stock gauges, i like the look of the aftermarket gauges. i plan on using novaks ac relocation brackets as well because i dont want to notch the frame. i plan on keeping it for a very long time so i wanna do it right the first time.
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Old 01-27-2016, 07:43 PM   #13
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Quote:
Originally Posted by DuckHunter57 View Post
yes i found out after i got home and researched a little more, ive pulled all the egr off and will be deleting it. as far as the transmission i have a buddy that owned a transmission shop for years as a side gig and he is going to build the transmission and replace the shaft for me. yes i plan on using novak for the adapter for my 231 transfer case. as of right now i dont plan on running the stock gauges, i like the look of the aftermarket gauges. i plan on using novaks ac relocation brackets as well because i dont want to notch the frame. i plan on keeping it for a very long time so i wanna do it right the first time.
Last question. Are emissions testing required for where you live? Like plug it into the computer.
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Old 01-27-2016, 07:44 PM
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no sir
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Old 01-27-2016, 08:02 PM   #15
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It has a cable throttle body. That tells you its a 99-01
Before you install your engine you should pull the oil pan and everything off the front of the engine. Port and shim the oil pump and install a new suction tube o-ring. Those are the biggest issues with the LS engines. The Oil pressure plunger will get stuck open slightly causing low oil pressure. It still has enough pressure that it doesn't kill its self, but wont let the factory gauge read.
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Old 01-27-2016, 08:29 PM
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10-4 thanks for the tips. i just looked up all that you mention and im sure i could handle all that. anything else you would do to it or suggest i check before i start? i did replace the plugs and plug wires already. went with the msd super conductor wires and ngk TR55 plugs. i noticed one of the coil packs has a broken piece where the connector clips in so i may have to replace that coil. i will be using the sanderson headers and wondering if i shouldnt install a cam while its out and easy to get to? would love to squeeze all the fuel mileage i can out of it lol. i have the cruise control box but not quite sure how it will work out, kind of wished i would have waited and gotten a dbw but i figured the cable would be a easier install.
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Old 01-27-2016, 09:02 PM   #17
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Inspect your front/rear main seals. It's much easier to change outside the vehicle! haha It would be ideal to change the cam when you have to oil pump, water pump, and front cover off the engine! I will be doing it to mine soon. I'm installing a set of port and polished heads also! Check out Crane cams. They have a Truck series cam that gets good reviews.
Just get a good used set of coils so you have spares. Do not waste your money upgrading to aftermarket coils. The ignition system is very good!
Its about smiles per gallon with an LS. I have a shit eating grin most of the time when I'm driving around! Haha Especially when the roads are damp and I smoke the tires(35" BFG KM2" off from a 30mph roll!
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Old 02-04-2016, 04:27 PM   #18
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What are you guys doing for exhaust? Single,dual,side exit? Cats? 4 o2 sensors? Anybody have to go through emissions testing like I do in CT? Thanks
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Old 02-05-2016, 06:11 AM   #19
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I'm running 2.5" off my headers. The drivers side goes down and around the front of the oil pan sump. The passenger side goes down and back. I have a 2.5"-3" y-pipe one 3" highflow cat and a magnaflow muffler then it dumps before the rear axle. I will look to see if i have any pic tonight.
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Old 02-05-2016, 04:09 PM   #20
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I have 2" coming off my manifolds running down both sides, dual mufflers dumped just before the rear axle. Cleared everything just fine and no extra heat issues. Im 5000+ miles on my 5.3 4l60e swap and no issues. 2 Upstream o2 sensors are all thats needed/wanted.. I dont have emissions testing but I wouldnt think for a minute that it wouldnt pass.
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Old 02-05-2016, 04:22 PM   #21
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I installed a small custom cam spec'd by Pat G. LS1 heads and a custom tune by jeff out of baton rouge louisiana.. every extra bit of power is nice. I cut down my own harness, used the novak bolt in engine mounts, got an s10 transfer case adapter from a salvage yard to adapt the 4l60e to the 231 transfer case. Also combined a chevy 231 and the jeep 231 t case for strength. The only thing I see commonly in build threads and even the novak site says its ok to use the stock fuel pump minus the regulator... this is NOT A GOOD IDEA... I load tested the fuel pressure using the stock pump and novak regulator delete and was dropping to 30 and less psi at 5000rpm and above. This is a good way to fry an engine.. Have since upgraded to the walboro 255, it literally fit right in place of the stock pump and I also installed 3/8 fuel line and used the stock 5/16 as a return.. fixed the fuel issue! Im rambling on, just trying to throw ideas your way.. be happy to help any way I can if needed, good luck! Also, the bumber looks sweet.. look forward to seeing the jeep "finished" (no jeep is ever finished!)

-Brian
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Old 02-05-2016, 05:08 PM   #22
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I'm running a stock fuel pump setup on my swap and it hasn't had any issues. I got lucky since my LJ is a 2005. The have a 60psi system from the factory like the Silverado. I just had to change the line going from the hard line to the fuel rail. Only 2005-2006 have the 60psi return-less system. They also use a different power steering system, and the high pressure line uses the same fitting as the GM pump.

Jeepsurgeon- could you post some pics of your exhaust routing?
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Old 02-05-2016, 05:28 PM   #23
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Yes, 05 and 06 are fine on the fuel issue, mine is a 98 and if im not mistaken his is a 99. Regardless, Novak says the fuel pump is sufficient.. i assume they havent load tested it at high rpm, everyday driving it is fine.. higher rpm not so much. I used the chevrolet power steering pump and purchased an 05 tj line to use.. Screwed in both sides just fine! good recall Green LJ, I had forgotten about the power steering. Yes, I will snap a few pics asap.. I used stock camaro headers due to fitment issues, truck wouldnt fit between frame rails, I had tried to use sanderson headers and another brand suggested by novak on a cj7 swap and they didnt fit so I didnt bother wasting time with them on the TJ. If memory serves me correctly corvette manifolds didnt fit (maybe hugged the block to tight and hit the mount?) , truck manifolds dumped into the frame, I ended up using camaro manifolds which sat in like they were made for it.
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Old 02-05-2016, 05:34 PM   #24
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Quick side note while im sitting here, I also used Superior radiator for my swap.. found on ebay where they listed one and made an offer.. was 180 dollars plus shipping I think, First one had a small leak in the corner, called them up and they had another one shipped out the next day with a return label for the first one. Very easy to work with and would recommend them, Im in south louisiana and havent had a heat issue yet. Im running a Syclone electric fan from summit.. works like a champ. I have a few pics on my phone I will upload later and I will snap a few of the exhaust routing as well.
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Old 02-05-2016, 05:44 PM   #25
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This is the clearance of the manifolds and the engine mounts.. more to come tomorrow.
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Old 02-06-2016, 05:57 PM   #26
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A few pics I snapped today of the exhaust.
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Old 02-06-2016, 05:59 PM   #27
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and one or two more..
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Old 02-06-2016, 06:06 PM   #28
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As I read more I remember more of what I did, for A/C relocation I used ls1bracket.com and a pancake compressor, it worked out nicely. I also kept the stock computer to run the factory gauges, lots of studying diagrams but finally got them to work just fine- except the Tach, didnt want to spend the money on the tach box to change the signal so I mounted a small tach on the dash..
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Old 02-08-2016, 07:16 AM   #29
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Nice work guys,Thanks for all the info!
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Old 02-15-2016, 09:37 AM   #30
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I think I am in the right place for the information I'm looking for. Good info here. Keep it up. Somebody please elaborate on hooking up stock gauges.

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