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mcpherson's YJ Build Thread


mcpherson

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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'





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)





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




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
 


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mcpherson

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City, State
Cumming, GA
Year, Model & Trim Level
'98 XLT, '88 YJ
Wire harness from the donor XJ:


Yes, it really is that bad:


The rear of the wrangler full of the XJ 4.0 engine parts
 




mcpherson

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City, State
Cumming, GA
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'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:


Progress Pictures:




4.0 sidepiece of block and bolt holes
 




BradR

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'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
 




mcpherson

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'98 XLT, '88 YJ
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

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. ;)
 




BradR

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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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mcpherson

Active Member
Joined
May 26, 2007
Messages
253
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City, State
Cumming, GA
Year, Model & Trim Level
'98 XLT, '88 YJ
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! :)

I hear ya bud, decisions can be hard to make. Just flip a coin and stick with it. :thumbsup:
 




mcpherson

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City, State
Cumming, GA
Year, Model & Trim Level
'98 XLT, '88 YJ
As you can tell, new & old head:


Backside of the new heads water slots:


Somewhat not organized 4.0 parts:


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.
 




mcpherson

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City, State
Cumming, GA
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'98 XLT, '88 YJ
More goodies arrived yesterday.

Obviously this is a FlowKooler Water Pump, Model 1747:



Fuel Pump Block-Off Plate:


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


Novak Shifter Assembly for New Process - 231 Transfer Case:
 




mcpherson

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City, State
Cumming, GA
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:




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


 




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