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Discussion Starter · #1 ·
\'94 YJ 2.5L to 4.0L Swap?

I've got a '94 YJ with a tired 4-popper (2.5L) under the hood. I've recently acquired the rights to '94 Jeep 4.0L HO (bone stock) engine and I'm considering a swap. Does anyone know if this is a piece of cake job, or an engineering nightmare? From the outside this swap looks like a "no-brainer" but then again.....AIN'T NOTHIN' CAN BE EASY!...Thanks in advance for any info!
 

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Re: \'94 YJ 2.5L to 4.0L Swap?

you will need new motor mounts.. exhaust.. driveshafts.. not sure about the computer systems.. i deal the with the old stuff.. but those are what i can think of... what tranny... might need a bell housing..

survival is instinct, but living takes guts
 
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Discussion Starter · #3 ·
Re: \'94 YJ 2.5L to 4.0L Swap?

I'm in the process of doing this right now on my 93 4-banger. Basically, get everything out of the engine compartment that is even touching the engine--accessories, wiring harness, computer, exhaust manifold, intake manifold, throttle body, etc...you will need it, get the bellhousing, tranny, transfer case (the 4.0 has a 23 spline input gear, the 2.5 has a 21 spline), and driveshafts. You could save a little money by swapping the input gear on your transfer case. The radiator may be the same, but I still haven't gotten a clear answer on that. If you don't get everything off of the engine initially, you'll be suicidal /wwwthreads_images/icons/crazy.gifabout halfway into the swap when you are shelling out a lot of money for bits and pieces. I'd be curious as to how much you got the donor 4.0 for, and also labor on the swap if you aren't doing it yourself. I have prices of $2000-$3000 for all parts on a couple of low mileage wrecks. Labor quotes have run from $500 to $2500. As far as swaps go, it should be a no brainer since it was a factory option on the same frame. No custom bracketry or machining necessary. Good luck!

If we're not supposed to eat animals, then why do they taste like meat?
 
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Discussion Starter · #4 ·
Re: \'94 YJ 2.5L to 4.0L Swap?

Thanks for the info! I figured it would be interesting to say the least getting everything together, then cramming it under the hood. I'm not sure if I'm ready to tackle that kind of labor myself. As for the 4.0L engine, I picked it up for 500 bucks, from a wreck. The insurance co. totaled the jeep, for suspected frame damage.
 
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Discussion Starter · #5 ·
Re: \'94 YJ 2.5L to 4.0L Swap?

Complete swap (engine, computer, harness, accessories) should run no more than $1500. $1000 if you shop around. It's really a very common engine, and you should have no problem finding one.

take care,
mike
 
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