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Old 08-01-2018, 12:52 AM
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5.2 Magnum YJ

I recently bought a 1980 CJ7:


My plan was to swap in a more modern, fuel injected V8 and 5 or 6 speed tranny, so then I bought this:


It's a 1995, 5.2L (318), 5 speed 4x4 Dakota, which means it has an AX15 tranny and an NP231.
Unfortunately, a bunch of forum reading lead me to the conclusion that a CJ7 has a couple of disadvantages when doing this swap, most importantly the frame is narrower, the drop is on the other side, and the gas tank isn't set up for the pump for fuel injection.

I know these are issues that can be overcome, but I finally decided, mainly because my wife and I have 3 TJ's and another YJ between us, that I would build a YJ with the magnum motor. By using the YJ I don't need another fuel pump, no worries about adapters for the t case, and, best of all, I can swap wheels and tires around amongst all our jeeps without worries.

Decision made I swapped my youngest son his first jeep, (one of his buddies flipped it and he ended up dealing it to me for one of my other jeeps), and a parts YJ I had picked up real cheap for a 1995(?) 4cyl 5spd his girlfriend gave him. (No, really she GAVE it to him!!)

I also threw in the 1999 Ram I had picked up a few years ago to try this same swap, (although that one is an auto and a 5.9(360)), that you see right behind it. (The jeep in the far background is the one that got flipped).
Now almost everything I know about working on jeeps came from jeep forums and youtube videos so a complete drive train swap should be quite an adventure.

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Old 08-01-2018, 01:06 AM
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Step 1 was to get rid of this horrible, heavy front bumper, (this thing is EASILY 50 pounds!!).
It took some fighting and yet ANOTHER set of torx bits but I got it off.
I have the best wife EVER! Went in the house to use the facilities and when I got back she was in the middle of taking off the front fender

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Old 08-01-2018, 01:16 AM
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Got back at it tonight, (one night off between two weeks of third shift), and got the whole front end stripped down and was working on trying to get the whole wiring harness off intact.

By the way, does anyone know what this is?

It's some kind of two plug set up with covers that mounts to the battery tray and is part of the engine harness... Like i said in the OP I'm not an expert but I've been under the hood of several YJ's and have never noticed it before.
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Old 08-01-2018, 01:25 AM
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Like I posted above, I was TRYING to get the wiring harness off intact.


As this picture shows I got in pretty deep pretty fast. I was under the impression that the wiring harness should be in two pieces, the under hood and the in cab. Somehow, I have a mass of wiring that heads into the tub in the center through a rubber grommet that has no disconnect. I started trying to unwire the dash but wound up stymied by not having a steering wheel puller. I'm going to have to rent one tomorrow so I can pull the dash out completely and then figure out how to somehow neatly get all this wiring out.
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Old 08-01-2018, 01:27 AM
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By the way, I am using imgbb to host these images and am manually resizing them as I post them here and it isn't working right.
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Old 08-01-2018, 01:35 AM
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So, I have the summit headers for the swap and a set of the AA engine mounts. I plan on using pretty much everything from the dodge that I can because the YJ is in pretty rough shape. I hope to be able to figure out how to use the dodge steering column because it has tilt and also delay wipers, (I know you can adapt some from an XJ but I already have the dodge here), I'll probably fab something for a dash and use as much of the dodge dash as i can, instrument cluster... maybe heat and ac controls and vents???
Drive train wise my first try is going to be putting an SYE that I have into the dodge T case if possible and am shooting to get the tranny and t case as close as possible to the stock location without causing myself a ton of heart ache.
I'm going to run the stock axles for now but have an 8.8 with 4.10's that I will put in the rear if/when I grenade the one that's in there.
The first pass of this build is probably going to be ugly because I am going to go Roadkill style and shoot for running and driving ASAP while dealing with ugly later, at least as long as that doesn't mess me up further down the line.
I'll post up as I do stuff, and please! If you know something I need to feel free to toss in some advice, I've done alot of reading and researching but am not an expert and am working without a net here.
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Old 08-01-2018, 02:11 AM
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I'm feeling about like an idiot right now. Conner told me the jeep was a 1995, and, other than the fact that meant I had a gas tank set up for FI I didn't give it another thought.
Pulling the wiring off though, I noticed the TBI type set up? Carb? Not real sure what it is, but it isn't MPI, and then realized there's no computer under the hood, so this is either an older YJ or someone has done some refitting somewhere along the line.

I sure hope I can swap in a later fuel tank if needed, but, other than that, I guess it doesn't really matter much
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Old 08-02-2018, 10:11 PM
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I did some measuring this morning and the dakota dash is, believe it or not, 2 inches narrower from door pillar to door pillar, than the yj is.

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Old 08-04-2018, 10:07 AM   #9
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There might be a couple of issues with the mopar v-8 swap. First off, the fuel pump for a 4.0 might not put out enough pressure for 5.2 engine. Some of the early fuel injected ford pickups had a frame mounted pump. If you don't have a computer, there are a number of aftermarket computers. I had a 5.9 in a 89 cherokee for a while with a Megasquirt computer.
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Old 08-04-2018, 03:40 PM
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Quote:
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There might be a couple of issues with the mopar v-8 swap. First off, the fuel pump for a 4.0 might not put out enough pressure for 5.2 engine. Some of the early fuel injected ford pickups had a frame mounted pump. If you don't have a computer, there are a number of aftermarket computers. I had a 5.9 in a 89 cherokee for a while with a Megasquirt computer.
Thanks, I will check into it.

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Old 08-11-2018, 06:01 AM
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Quick update. Two weeks of third and now a family camping trip. Got a nice check this payday though so may be able to get a lift once we get back.

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Old 08-19-2018, 07:25 PM
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Engine and tranny are out of the yj! Next step will be to get the dakota in and the drivetrain and dash pulled!

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Old 08-20-2018, 09:16 PM   #13
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Just noticed your build thread, a couple thoughts. The computer (ECM) is located under the dash above the heater core. The wires going through the fire wall with no connector go to the ECM. The plugs on the battery tray also are used for ECM diagnostics. You won't use any of these with your swap. Hope this helps a little. Also the fuel pump for the 4.0 should fit your tank and also should have plenty of psi.
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Old 08-20-2018, 09:17 PM
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So i can just swap in the in tank unit from a later model yj?
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Originally Posted by gbyenko View Post
Just noticed your build thread, a couple thoughts. The computer (ECM) is located under the dash above the heater core. The wires going through the fire wall with no connector go to the ECM. The plugs on the battery tray also are used for ECM diagnostics. You won't use any of these with your swap. Hope this helps a little. Also the fuel pump for the 4.0 should fit your tank and also should have plenty of psi.
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Old 08-21-2018, 08:30 AM   #15
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This what I understand, you'll probably have to add a fuel return line if thats what your dakota had.
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Old 08-21-2018, 02:44 PM   #16
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Quote:
Originally Posted by workgoats View Post
There might be a couple of issues with the mopar v-8 swap. First off, the fuel pump for a 4.0 might not put out enough pressure for 5.2 engine. Some of the early fuel injected ford pickups had a frame mounted pump. If you don't have a computer, there are a number of aftermarket computers. I had a 5.9 in a 89 cherokee for a while with a Megasquirt computer.
The 4.0L is plenty big enough for a 5.2L Magnum system. However, most people replace the 5/16" line with 3/8" line...
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Old 08-21-2018, 02:58 PM   #17
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Originally Posted by steelrfn View Post
Engine and tranny are out of the yj! Next step will be to get the dakota in and the drivetrain and dash pulled!

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One thing to note as you put the new engine in place - the Dakota trans is clocked a little more vertically, meaning the front output shaft is "down" a bit more, which may cause you to have some interference with your t-case and crossmember. A simple fit would be to buy a clocking ring or drill new mounting holes to match the YJ clock.
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Old 08-21-2018, 03:22 PM
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The 4.0L is plenty big enough for a 5.2L Magnum system. However, most people replace the 5/16" line with 3/8" line...
Currently planning on making as few changes as possible so will try the stock line. If it ends up being an issue i will upgrade as necessary. Most likely i will upgrade it later anyhow.

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Old 08-21-2018, 03:23 PM
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Thanks for the heads up, i will watch it closely.
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One thing to note as you put the new engine in place - the Dakota trans is clocked a little more vertically, meaning the front output shaft is "down" a bit more, which may cause you to have some interference with your t-case and crossmember. A simple fit would be to buy a clocking ring or drill new mounting holes to match the YJ clock.
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Old 08-21-2018, 03:25 PM
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Heres the portion of the dakota dash i am going to swap in. It has all the gauges, heat/ac controls, stereo mount, etc. If possible i will do the rest of the dash as well

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Old 10-01-2018, 02:02 AM
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Sorry for the long delay, currently have three jeeps down. Exhaust work, clutch repairs, brakes, and inspections.

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Old 04-26-2019, 04:20 PM
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Finally got back to work on the swap. Spent the winter working on other things or hiding from the cold.
Drivetrain and wiring are all out of the Dakota. Next step is cleaning up the area where the old mounts were and where the new mounts should go on the jeep.
I will be putting a SYE in the transfer case, so that might come before anything else, since separating it would lessen the load on my harbor freight engine hoist, which already lost one wheel during the exteaction.... which was WAY uglier than I had hoped.

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Old 04-26-2019, 04:25 PM
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I did find that the starter is on the driver's side, but am hoping that since others have used this bell housing everything will clear.i have a 1 inch body lift to go on when I install the tub, hopefully between that and the engine mounts I can drop the whole package in pretty much as is. Other than cutting the wiring harness to the rear of the truck about 3/4 of the way back and tearing the wires loose to the o2 sensor I forgot to move I haven't done anything but disconnected the under hood harness from the inside one. If my thinking is right I could theoretically wire up the jeep fuel pump, reconnect the two harnesses, toss a battery in it, and start it.
We'll find out in a couple of weeks, wish me luck.

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Old 04-26-2019, 06:13 PM   #24
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Good Luck, L.M.
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Old 04-26-2019, 07:50 PM
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In case anyone is wondering the Dakota dash, or even any decent sized portion of it, will not fit.

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Old 04-27-2019, 08:27 AM   #26
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This excites me to see these builds moving again. Winter sucks. I have a 96 GC with a 5.2 waiting to be torn apart for my 93 YJ with the 2.5.
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Old 04-27-2019, 05:02 PM
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Does anyone have a photo of the advance adapters motor mounts installed? I feel like a complete idiot, but the kit I bought, (713095), says it fits a YJ but unless I am doing something horribly wrong it has to be mounted to either the top or bottom of the frame, not the side, and there doesn't seem to be any adjustability to it.

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Old 04-27-2019, 05:04 PM
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This excites me to see these builds moving again. Winter sucks. I have a 96 GC with a 5.2 waiting to be torn apart for my 93 YJ with the 2.5.
Best of luck! I am really excited to be moving forward on this. I have been wanting to build a v8 jeep since I bought my first 4cyl YJ... which is, by a weird twist of fate, the frame I am using

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Old 04-28-2019, 02:59 AM
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I think I figured out the motor mount issue... oddly enough from looking at the picture I took to post in the v8 discussion thread.

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Old 04-28-2019, 07:27 PM
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Nope, still cant get it, motor is way too high if the mounts are flush and even with frame

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