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Old 01-09-2020, 11:45 AM
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Junior - My 04 TJ 5.3 Swap Build Page

I started a swap in high school with my grandpa, 91 YJ that we rebuilt a 350 for but stalled out after the engine build. We sold the jeep and gave away the engine and I've always wanted to finish the project. My grandpa was a Jr. so I'm naming my new to me Jeep "Junior", he passed away this year after a long and successful life.

I bought my 2004 4.0 NV3550 TJ in June of 2018. I bought the 5.3L April of 2019, along with the 4L60E transmission. I'm using pretty much all Novak conversion pieces and I'm videoing along the way, I won't post videos to youtube until the swap is done and successful.

Right now, I'm almost done cleaning up and doing basic maintenance on the 5.3. New oil pan gasket, new valve cover gaskets, new intake manifold gasket, new spark plugs and wires, new throttle body gasket, installing jeep water temp and oil pressure senders, replaced knock sensors with new harness, extracted a broken manifold bolt, new injector seals, install new headers (not fully until after it's in and set in the Jeep). Just need to install front accessories, including the A/C relocation bracket and new compressor, and I'll be ready to start on the transmission.

I've done a ton of research and "invested" a lot of money into this swap, let me know if you have any questions!

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Old 01-09-2020, 09:41 PM   #2
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Very nice. Keep us posted.

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Old 01-10-2020, 11:39 AM
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Starting to look like a complete engine and the transmission is getting degreased, new seal, new filter. Jeep temp sender and oil pressure sender coming today. About to start the real work, removing the old drivetrain from the Jeep!
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Old 01-11-2020, 12:11 PM   #4
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Coming over from Pirate so I can post on your build thread! You can message me if you get stuck and need help.



I went with autometer guages. Ran sending units from them for the oil and temp. Speedo and tach went to my howell harness. fuel psi and trans temp added. Add a eternal oil coller for the 4l60. Cheap insurance and easy install.
Ran new sender for fuel gauge as well.



I went all novak minus the radiatior. I bought mine from a guy in MI that has them for LS swaps. Cheaper and works 100%.


If you are using the Np231 you will have to change the output shaft in the 4l60 with Novaks kit. Also SYE for the xfer case.


Wiring is a breeze with these. I kept all my notes


Talk soon!
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Old 01-11-2020, 12:12 PM   #5
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Quote:
Originally Posted by longhorn84 View Post
Starting to look like a complete engine and the transmission is getting degreased, new seal, new filter. Jeep temp sender and oil pressure sender coming today. About to start the real work, removing the old drivetrain from the Jeep!

Make sure you check those headers. Not many options to fit between the rails!
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Old 01-11-2020, 04:19 PM
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Thanks Aaron, I got the headers from Novak so hopefully they know what fits. I just dropped the tranny off to be rebuilt with the new output shaft installed. I'll start on the SYE I got from terraflex next week.

I do have rear control arms and springs from currie I bought last year but never installed. Since i'm going with new driveshaft and SYE, I figure I need to install those before I measure for driveshafts. Just another one of those projects that takes time away from the actual swap.

Next steps are pull jeep drivetrain, cut out old motor mounts, test fit drivetrain, get professional to weld motor mounts in, plumb fuel system, install wiring and then test fire!
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Old 01-12-2020, 05:08 AM   #7
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We are headed down similar paths. Good write up. Good luck.
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Old 01-19-2020, 10:32 AM
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No turning back now, working on getting everything ready to pull the 4.0, so far so good just a few new scrapes on the hands!


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Old 01-20-2020, 01:56 PM   #9
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Keep going, you gonna love it, looks like this when you're done.
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1995 YJ. That's it...from Jeep. 5.3L Chevy LM7, 4L60e, NV233C Transfer Case with electronic Shift, 2.5" RC Lift. 8.8 Ford Rear with Yucon Posi Grip, 4.10 Gears, 33x12.5x15 KM2's. Marshall Instruments Gauges, Sick Speed Racing Seats.
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