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mcpherson's YJ Build Thread

Discussion in 'Jeep' started by mcpherson, April 19, 2011.

^^Searches ExplorerForum.com^^



Do Not Sell My Personal Information


  1. mcpherson

    mcpherson Active Member

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    City, State:
    Cumming, GA
    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    Figured this would be just as good as anywhere to document my Jeep build thread.

    For as long as I could remember I have always wanted to own a Jeep (dont worry, the explorer still has some plans ahead of it and will not be going anywhere.) So after some searching I located a deal on a Jeep and purchased it. I had all best intention of leaving the orginal engine with carberator and transmission, well on the hour long drive home this thought change very quickly and 2 days later I purchased an XJ donor vehicle for the complete engine, wireharness and computer. As further plans went, I ran some compression test on the XJ jeep and it wasnt looking so good; so the next best thing was to test the YJ engine and voila, it came back with excellent results. It was concluded that I was going to purchase a rebuilt cylinder head (4.0 Cast #7120) and with some modifications mount it on the pre-existing 4.2 YJ block.

    Stock Specs:
    • Engine - 4.2L I6, 2-B Carb (160,000+ miles)
    • Transmission - TF999
    • Trasfer Case - NP231
    • Front Axle - Dana 30
    • Rear Axle - Dana 35
    • Axel Gear Ratio - 3.54:1
    • Suspension - Stock
    • Tires - 31'

    [​IMG]
    [​IMG]


    Engine Swap
    - Purchased a donor 95' XJ 4.0 Sport

    - Parts List:
    • Remanufactured Head Cast#7120 (RockAuto.com)
    • Motor Oil (Local Auto Store)
    • Spark Plugs (Local Auto Store)
    • Spark Plugs Wires (Local Auto Store)
    • Distributor Cap (Local Auto Store)
    • Rotary Button (Local Auto Store)
    • Water Pump - FlowKooler (Quadratec.com)
    • Thermostat (Local Auto Store)
    • Oil Filter (Local Auto Store)
    • Serpentine Belt (Local Auto Store)
    • Upper Gasket Set
    • Crankshaft Seals (Local Auto Store)
    • Electric Fan
    • Exhaust Studs
    • Electric fan Control Unit (DCControl.com)
    • Fuel Pump (RockAuto.com)


    [​IMG]
    [​IMG]

    Transmission Swap
    - AW-4 Transmission from an 88' XJ

    - Parts List:
    • Novak Shifter Assembly for New Process - 231 Transfer Case
    • Front & Rear Main Seals
    • Filter & Gasket
    • Transmission Fluid - 8 Quarts

    [​IMG]
    [​IMG]

    Misc & Replacement Parts (Other then engine/transmission related)
    • Soft Top & hardware - Bestop 54599-15 Supertop Black Denim Soft Top with Tinted Windows (Amazon)
    • Cleaner - Bestop Protectant & Vinyl Window Cleaner (JC Whitney)
    • Front Floor Mats - PLASTICOLOR (JC Whitney)
    • Rear Cargo Mat - PLASTICOLOR (JC Whitney)
    • Black Lower Door Hinge Brackets - Smittybilt 7607 (Amazon)
    • Black Windshield Hinge Brackets - Smittybilt 7603 (Amazon)
    • Black Complete Hood Kit - Smittybilt 7699 (Amazon)
    • Extreme Black Sport Handle - Smittybilt 769310 (Amazon)
    • FAIRCHILD INDUSTRIES 13 Piece Weatherstrip Kit (JC Whitney)
    • XJ Hayes Manual (Local Auto Store)
    • YJ Hayes Manual (Local Auto Store)

    Soon to be here after mods:
    • BDS Suspension - 3-1/2" Lift Kit w/Shocks
    • M.O.R.E. Front & Rear Boomerang Shackle (5/8" lift)

    Related Information:

    Engine Specific

    Transmission Specific
     
    Last edited: August 18, 2011
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  3. mcpherson

    mcpherson Active Member

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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    Wire harness from the donor XJ:
    [​IMG]

    Yes, it really is that bad:
    [​IMG]

    The rear of the wrangler full of the XJ 4.0 engine parts
    [​IMG]
     
  4. mcpherson

    mcpherson Active Member

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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    Well, being that it was Easter weekend I only achieved a few hours to work on this. Some parts came in last weekend, one being the fuel pump so below is a picture of it. The other photos are of just of progress and misc.

    E2000 - Fuel Pump:
    [​IMG]

    Progress Pictures:
    [​IMG]

    [​IMG]

    4.0 sidepiece of block and bolt holes
    [​IMG]
     
  5. BradR

    BradR Active Member

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    City, State:
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    Year, Model & Trim Level:
    '99 EX 4.0 OHV
    So you're keeping and fixing both Jeeps and the Explorer?
    I'm so lost. lol.

    I love Jeeps and would own and drive one all the time, but I would be WAY to cold in the winter and would then hate it. :p
     
  6. mcpherson

    mcpherson Active Member

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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    I went back and forth on the thought of to keep or not to keep the Explorer, but I enjoy driving it so much. Plus I have some thoughts of what I would like to do with it down the road. As for you being lost I think the term "It's a jeep thing" covers it, but hey not to worry I am lost also with this also, I suppose keeping the Explorer is keeping me lost. I don't like the cold myself, so it does have the hardtop for the winters and worse case the Explorer is there unless its receiving the a new axle or 2... and the jeep may need that rear 8.8 axle, opps did I just write that. ;)
     
  7. BradR

    BradR Active Member

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    Haha, you're my kind of guy.
    My buddy has a Jeep, I kind of understand the Jeep thing, he just doesn't do it right. lol.

    I'm having a similar problem trying to decide what to keep or sell with my Mountaineer or Explorer, as I can't afford 2, and don't have a need for 2 at the moment... while I can get my hands on a supercharged302 for the Mounty, I don't really want to do it, and I'm tired of the Explorer, I've owned that a year and a half and I have nothing left to do with, and I want a street truck, my mind is just full of ####. lol. There's a lot more going on than what I just said. But I don't wanna clog up your thread here.. lol...

    This is his 87 YJ? I think, IDK! :p 4cyl 5 speed that goes tick tick tick.
    And my Explorer in the back ground yay! :)
     

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  8. mcpherson

    mcpherson Active Member

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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    I hear ya bud, decisions can be hard to make. Just flip a coin and stick with it. :thumbsup:
     
  9. mcpherson

    mcpherson Active Member

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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    As you can tell, new & old head:
    [​IMG]

    Backside of the new heads water slots:
    [​IMG]

    Somewhat not organized 4.0 parts:
    [​IMG]

    Discovered this while detaping the the YJ's wiring harness. This will be replaced and the rest of the vehicle will be under close attention.
    [​IMG]
     
  10. mcpherson

    mcpherson Active Member

    Joined:
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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    More goodies arrived yesterday.

    Obviously this is a FlowKooler Water Pump, Model 1747:
    [​IMG]
    [​IMG]

    Fuel Pump Block-Off Plate:
    [​IMG]

    Dial Indicator (because each setup can be different in regards to Push-Rods, I purchased this to verify what will and will not work):
    [​IMG]

    Novak Shifter Assembly for New Process - 231 Transfer Case:
    [​IMG]
     
  11. mcpherson

    mcpherson Active Member

    Joined:
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    City, State:
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    Year, Model & Trim Level:
    '98 XLT, '88 YJ
    Also got around to removing the head form the YJ, and just as suspected the cylinders look pretty good:
    [​IMG]

    [​IMG]

    Was also able to have most of the wiring pulled to the side, 3 reasons for this is:
    1. remove old engine wiring
    2. clean oil off wires
    3. inspect all wires for cuts & bare wires
    [​IMG]

    [​IMG]
     

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