Swap: H0 4Wd Into Renix 2Wd

[comenschen]

Yeah yeah, I've searched. I think I have it covered. just wanted some of you OG's to chime in if I missed something. Here goes.

 

Truck is a 89 4.0l ba10 2wd. Blew head gasket this morning. Truck already has 4wd front axle with matching 4.10 rear. Was about to put a 96 XJ AX15 in when this happened :(

 

The engine had a knock anyway, so this is what I'm going to put in:

 

-91 HO engine/intake manifold/HO APN header. I know I need to adapt the TPS and weld an O2 bung into the header. Then will use all other Renix stuff. I'll just make my own intake past the TB.

 

-96 XJ ax15. I already have the proper pilot bushing and the clutch hydraulics. Will use original renix clutch and flywheel.

 

-91 XJ np242 OR 98 dakota np231. I think I'd rather put the 242 in. I have the linkages for both.

 

-I have a variety of front and rear driveshafts. If none of them work, I'll modify something to work.

 

-I have the 2wd ba10 crossmember and an XJ 4.0 4wd AW4 xmember. Will one work? If not I'll make my own.

 

Any surprises I'll run into? Basic stuff is okay...it's the stuff i didn't think of that I'll need to order parts for that I'm concerned about.

[comenschen]

Fuel lines...forgot about that one.

[cruiser54]

Take from this what you need. Personally, I'd keep the Renix intake but use the HO exhaust manifold.

 

Cruiser’s HO into Renix Swap

This swap is easier than some will lead you to believe, generally those who have never done it. Those of us who have done it, like myself, will share with you the things that need to be done for a successful swap. Just think of it as swapping in a long block.

The HO and Renix have some differences but none that can’t be overcome very easily.

Any HO engine from an XJ or ZJ through 1998 can be used. One running change was that the rear of the head was no longer drilled and tapped for the temperature gauge sender beginning in the 96 model year. The sender can be relocated to the threaded hole in the thermostat housing taken from the HO engine. You’ll have to extend the wire to that location. Some brave souls even drill and tap the HO head for the sender.

You will be using the intake and exhaust manifolds from your Renix, along with all your sensors and wiring. Since the intake ports of the HO are slightly different, you use the Renix gasket. Exhaust ports are identical.

You will need to use your Renix distributor as it is different than the HO because they use different fuel management systems. The flywheel or flexplate from the Renix must be used so your CPS gets the correct signals. The valve cover from the Renix allows you to keep your CCV system intact and requires no modifications.

The HO block will have a plug in the coolant galley on the driver’s side of the block, closest to the front, which needs to be removed so your Coolant Temp Sensor can be installed in it’s place just as it is on the Renix. It requires a 5/16” square drive or a modified 3/8” drive that has been ground down to fit. Do this before installing the engine.

As for the knock sensor, which is located just above the oil pan on the driver’s side of the engine about mid way, all the blocks I’ve seen are threaded for it. If not, I’ve heard they may be drilled but not tapped. Tap the hole if that’s the case.

 

Revised 07/24/2012

[jpnjim]

Use the later crossmember,

and you won't have to weld a bung in the header if you use an HO header to cat pipe

(I don't think the renix pipe will work with the HO header anyway)

 

Check the input spine count on the 91 242.

1991 was the year Jeep changed the AW4 from 21 to 23 spline.

Some have said early 91's didn't get the upgrade.

 

That's all I can think of right now,

good luck!

[jpnjim]

Fuel lines,

If you go with the HO intake,

I shortened & adapted the renix lines to fit the 91-95 HO quick disconnect rail fittings with a flaring tool.

Not the correct way, but it worked for me.

 

I also used the HO distributor as cruiser mentioned above.

 

HO throttle body also needs to use the HO throttle cable AND HO gas pedal assembly.

(Renix gas pedal won't give you wide open throttle)

 

 

Also,

Besides the fuel rail differences,

1996 engines are different from 87-95's because they use that main cap girdle under the pan,

and have a smaller cam to get back some of the low end torque they lost in 91 with the swap to HO intake & head.

 

Neither should really effect what you are doing,

but I thought it was worth mentioning.

[comenschen]

Thanks for all the tips!

 

I think for ease of getting it back together, I'll run the renix intake. Couldn't I just port match the renix intake using the HO intake gasket? I was going to pick up a full gasket kit and reseal the engine before I put it in. Would the intake gasket be the only thing different between a renix and HO gasket kit?

[cruiser54]

Thanks for all the tips!

 

I think for ease of getting it back together, I'll run the renix intake. Couldn't I just port match the renix intake using the HO intake gasket? I was going to pick up a full gasket kit and reseal the engine before I put it in. Would the intake gasket be the only thing different between a renix and HO gasket kit?

 

Use the Renix gasket and port match. Done this 3 times with excellent results.

[HOrnbrod]

I shortened & adapted the renix lines to fit the 91-95 HO quick disconnect rail fittings with a flaring tool.

Not the correct way, but it worked for me.

 

Could you explain this further Jim?

[jpnjim]

The quick release ends attach to a flat section on the hard line.

I was able to copy this well enough with a brake line flare tool.

 

IIRC,

doing the first step of a double flare, without folding the 2nd half of the double flare in on itself worked really well,

so far the joint has has held up much better than my memory of exactly how I accomplished it ;)

[HOrnbrod]

I see, thanks. I've got all the AN stuff I need to dump the plastic fuel lines and quick-connectors and am going to redo mine like this. Much more secure. Pic courtesy of MJ Mike. :cheers:

 

[mountainman]

renix sucks. toss everything renix and put in all HO. transfer everything from HO vehicle. lol

 

Thats my not renix friendly response. ;)

[comenschen]

HO vs renix.....I really couldn't care less. I just need this thing back up and running. Probably won't even bother to port match the intake (we'll see once I have the renix intake next to it). And now that I'm throwing my HO engine in this thing, my other truck will be getting a drivetrain that's in a whole other dimension of blasphemous. That's a story for another time and thread :)

 

Tore down the HO tonight to make sure I wasn't wasting my time. All bearings and pistons look pretty mint. Surprising, b/c the rest of the motor was black as tar inside. So should I be ordering a renix full gasket set tomorrow due to using the renix intake? Or do i need to order an HO gasket set, plus a renix intake gasket? :dunno:

[comenschen]

Oooh, almost forgot...I assume renix and HO head bolts are the same? Snapped one on the HO pulling the head. Not sure what the general opinion here is on reusing head bolts, however I'm quite sure the HO head has never been off until now. I'll just steal one off the renix if it will work.

[cruiser54]

Oooh, almost forgot...I assume renix and HO head bolts are the same? Snapped one on the HO pulling the head. Not sure what the general opinion here is on reusing head bolts, however I'm quite sure the HO head has never been off until now. I'll just steal one off the renix if it will work.

 

It will work. If your situation is truly as you describe, just use my write up and git r done.

[comenschen]

Well, head is out to be decked, gasket set won't be here until late next week. Going to go pull the old drivetrain out today, so I guess I'll update my project thread later tonite.