Who's Done a 2.5 to 4.0 swap

[FLMANCHE526]

First off is there any write ups on this. :help:

My truck is a 90 Swb 2.5 4x4 5speed

I wanna do this because i work on boats and have to tow them around town luckily i live in South Florida so no hills to slow me down but even then these boats really work that old 2.5. Ive had a couple xjs with the 4.0 and they pull just fine but i need the bed to haul parts and tools also. Ive already got a 4.0 in the shed that will be rebuilt soon an a donor 90 xj with a running 4.0. What should i do and anybody up for helping ill supply the beer. :cheers: :cheers:

[Pete M]

short answer:

 

1- remove everything from your truck except the axles

2- remove everything from the XJ and put it into your MJ

3- go have fun

 

:D

[btm24]

you say when and I'm there

 

Brandon

[64 Cheyenne]

you say when and I'm there

 

Brandon

 

Dude, he aint gonna give you beer.......

[FLMANCHE526]

Hey if he can do work ill give him a few! how far is Zephrhills from Punta Gorda/Arcadia

[btm24]

Hey if he can do work ill give him a few! how far is Zephrhills from Punta Gorda/Arcadia

 

i could help lol idk about 2hr's :( . I'm no mechanic tho but i would hand you stuff :rotf: no it was a joke if i had the gas to go that far i would tho. if you were only like 30 min i would tho sry man good luck with the swap tho. keep us all up to date and maybe we could meet up some other time like when i have a job :ack:

 

Brandon

[WBKrazy]

i'm about 3/4 of the way through the swap, i didn't really make a write up on it but can probably answer most questions you might have... for the most part removal of the old stuff is pretty straightforward, me and jim (maddzz1 on here) had my 2.5 and ax-4 out and on the shop floor in about 4-5 hours using nothing but hand tools, and the 4.0 and aw-4 in and bolted down in about the same .... pete is right; basically everything under the hood changes, and a bunch of stuff inside the cab as well... starting at the front, the radiator is much larger than the 2.5 one, so you have the remove the brackets that the radiator bolts to. you'll need to grab all of the engine bay wiring off the donor, and if your donor is an auto, you'll also need the harness that goes into the firewall; for at the end of it, under the glovebox, is the transmission computer, which you'll also need.. the cooling system is different, so you'll need the heater blend valve, the surge tank on the firewall and all the coolant hoses. the blower motor has a different power plug on a 4.0 truck, so you can either splice the correct plug in or just replace it altogether. the gas pedal is also different so you'll need to change that. the fuel lines are also different, i spliced the 4.0 fuel lines into the ones on the truck already down at the frame. that's all i can think of for now, if you need to know something else feel free to ask..

[mjeff87]

WBKrazy is spot on with his advice, here's somewhat of a writeup on my swap with some pics of what he's talking about...

 

viewtopic.php?f=7&t=11205

 

Jeff

[Eagle]

WBKrazy is spot on with his advice, here's somewhat of a writeup on my swap with some pics of what he's talking about...

 

viewtopic.php?f=7&t=11205

 

Jeff

Thanks for showing up, Jeff. I went looking for your thread yesterday when I saw this question, and I couldn't find it.

[FLMANCHE526]

Sounds Like alot of work i better wait till the weather Gets cool so i can get it done thanks for the info

[streetjeep2.5]

pm sent