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How difficult is the swap from the 2.5L i have now to a Ford 302?

8.8K views 7 replies 5 participants last post by  Neil F.  
#1 ·
After a trail riding trip this past weekend, I have come to realize that even though my 2.5L is a torque monster, it is woefully underpowered for road trips of any real distance, especially in the mountains. I have a 302 that I am working over, and am giving serious thought to putting it in my TJ. Thoughts? Have any of you made this swap before?

Thanks
 
#4 ·
The one consideration that is quickly forgotten is your State/County Emissions Testing if it is going to be street legal. If you have a 90's+ donor vehicle that you are pulling the 302 out of that has all the emissions pieces, then you might be okay.

But if you have a 1970's carb'ed 302, you can probably imagine the headache you are going to have trying to get it to pass testing in a TJ. Might even be impossible.
 
#5 ·
The motor is one I am going to have to rebuild anyway. It is out of a late 60's / early 70's truck, and a rebuild is a necessity anyway. I didn't think about the emissions/electronics aspect. I know there are donor vehicles around for that.

I guess my biggest question is motor mounts -- where would I install them? I also am planning in going to a 3" - 4" lift instead of the 2" lift I currently have. Will this require an entirely new suspension set up to support the extra weight? Also, will I have to have a Ford tranny, or is there an adapter to connect the engine & current tranny? Will the stock Jeep tranny hold up under the extra power?

Thanks again in advance!
 
#8 ·
I didn't think about the emissions/electronics aspect. I know there are donor vehicles around for that.

!
As indicated, those can be realistic factors depending on how youR inspections are handled (or you have a way around them). I see from your profile (helps to put it in your front info for all to see) you are in NC. Do the research (google) I took a quick search and the rules appear to be in line with a lot of areas. The engine must be from the year of the vehicle or newer (with all emissions equip) and meet emissions of the vehicle it's going into. Most emissions are checked via the OBDII. 60/70 engine is not going to have all the sensors for OBDII

NC Engine Swap Laws - V6 to V8 - HorsepowerJunkies.com Forums
 
#6 ·
I would not put anything with a carburetor into a tj. You are going to be doing far more work than is worth while. Your cheapest and easiest solution for a v8 swap is a magnum v8. Both the 5.2 and 5.9 are very common and by far easiest due to the fuel system and gauges working correctly. All but the engine mounts and radiator will be factory production parts that can be found in most junkyards.

If you did want a 5.0 the best one to use in your TJ would be an explorer 5.0 from 96-01. It's a nice little mass air motor with gt40 (96 only) or gt40p heads. Swap out the cam position sensor for a distributor and an a9l, or a9p CPU and you would have a good little runner.

Any v8 swap will require a new transmission as well. The ax5 can't even hold up well to the 2.5. An ax15 can be used with most v8 swaps. For the magnum v8 you need a bellhousing out of a Dakota with a v6. For all others you need to source a bellhousing and an expensive adapter kit as well. For an automatic you use the 44re, or 46re transmission for a magnum v8. You can retain your 231j transfer case with these transmission, but you need to swap in a post 1995 short 23 spline input shaft. They are common and most Dakota, cherokee, Durango, and ram vehicles used them.

The ford automatic is another story. You could try and find an adapter to retain the 231j, but I don't know of any for any of the ford automatic. At that point you need to than find a BW case that won't be to long. Or maybe an old C4 with a dana 20 out of an early bronco.