KletusJeeps
New member
Well my fellow Jeepz.com crowd here goes nothing....
In my recent adventure to take a tired 4 banger over to the power side I have learned just a few things.
If you ever have the desire to take your worn out tired 4 banger to a larger motor here is what it took for me. I started out with a 1995 YJ with an automatic and a 4 banger that had been misused and abused before I purchased it. So my plan was, back in September of '03 to take out the 4 and auto and place in something larger with a standard. I threw around the idea of a 6 or 8 cylinder and decided to go with the traditional inline 6 from jeep because I felt it would produce better low end torque than the 8 would without having to regear. Plus as we all know the inline 6 is the closest thing to bulletproof a jeeper can get. So I purchased an inline 6, standard transmission, and transfer case out of a wrecked 2002 tj.
Well there was no way I was going to get that I6 in without pulling that ole 4 out first so that is where I decided to start. I unhooked everything that was connecting that engine, transmission, & t-case to the body. All electrical harnesses, grounds, belts, hoses, drive shafts, 4wd clubs, and steering column all came out to make room to gut this gutless wonder. With the cherry picker it was a sinch pulling it all out as one part from fan to spline everything came out.
Now here is where the real work started... First thing is first and that was to cut the old motor mounts off cause they were only going to get in the way so they came out with a map gas torch and a sawzall. Now is also a great time to put in the master cylinder from a 95 and the pedals also from a 95 this way you can operate your stick shift rather than just look at it. So while the 6, stick, and T-case are out we put them all together because they are all going in as one piece and trust me this was TONS easier than putting in a transmission on my back in my driveway. So we lowered in the new hoss and looked at what we had to do for motor mounts. Now I ended up purchasing both 1995 and 2002 I6 motor mounts and using one of each because of the shock tower that connected directly in the way. So after attaching the motor mounts to the engine, making thousands of measurements and lifting and lowering the engine for drive train alignment for days we welded in the motor mounts and put bombproof rubbers on 'em.
So you think your half way done now right? :roll: wrong! you have crossed maybe the 1/3 mark if your lucky...
Now before you start trying to bolt anything together or attempt to throw any new stuff in go to your local hardware store and buy 6 of every single nut and bolt pairs they have on the shelves :lol: just trust me on this one.
So on we go making things work where they are not supposed to work... So we use the 95 4wd gear shift because the 02 is using some pansy small linkage that didn’t impress me much and while we are down there we might as well shorten our rear drive shaft by 4 fingers width plus a karate chop palm width. (Now please let a professional do this and don’t try it with your sawzall ... any good machine shop or drive line specialist can do it for about 50 George W's) Seeing as how we are still underneath the beast this 02 t-case doesn't line up the way the 95 did so an aftermarket perch and padding was needed as well as a few new holes in my skid plate. Seeing as how we are here we might as well put the slave cylinder on and bleed it.
Ok now that we are done with that the rest is easy only because im sort of cheating and putting a carb on and scrapping that ole mpi crap but don’t worry you’ll make money on the deal I sold almost all of my 02 jeep stuff for twice as much as it cost for parts this way.
So you need a 258 intake, motorcraft 2150, headers (I used pacesetters that needed to be altered a little but nothing drastic), distributor, cap, rotor, ignition module, regulator for your alternator, electric fan (gonna need it if you don’t change the radiator out), coil, and some know how on how to do a little of this.
So long story short, :lol: , it was certainly worth it but as you can tell this adventure started in September of last year and is just now over. Would I dare venture off this cliff again :?: I say maybe I would.
Kletus
In my recent adventure to take a tired 4 banger over to the power side I have learned just a few things.
If you ever have the desire to take your worn out tired 4 banger to a larger motor here is what it took for me. I started out with a 1995 YJ with an automatic and a 4 banger that had been misused and abused before I purchased it. So my plan was, back in September of '03 to take out the 4 and auto and place in something larger with a standard. I threw around the idea of a 6 or 8 cylinder and decided to go with the traditional inline 6 from jeep because I felt it would produce better low end torque than the 8 would without having to regear. Plus as we all know the inline 6 is the closest thing to bulletproof a jeeper can get. So I purchased an inline 6, standard transmission, and transfer case out of a wrecked 2002 tj. Well there was no way I was going to get that I6 in without pulling that ole 4 out first so that is where I decided to start. I unhooked everything that was connecting that engine, transmission, & t-case to the body. All electrical harnesses, grounds, belts, hoses, drive shafts, 4wd clubs, and steering column all came out to make room to gut this gutless wonder. With the cherry picker it was a sinch pulling it all out as one part from fan to spline everything came out.
Now here is where the real work started... First thing is first and that was to cut the old motor mounts off cause they were only going to get in the way so they came out with a map gas torch and a sawzall. Now is also a great time to put in the master cylinder from a 95 and the pedals also from a 95 this way you can operate your stick shift rather than just look at it. So while the 6, stick, and T-case are out we put them all together because they are all going in as one piece and trust me this was TONS easier than putting in a transmission on my back in my driveway. So we lowered in the new hoss and looked at what we had to do for motor mounts. Now I ended up purchasing both 1995 and 2002 I6 motor mounts and using one of each because of the shock tower that connected directly in the way. So after attaching the motor mounts to the engine, making thousands of measurements and lifting and lowering the engine for drive train alignment for days we welded in the motor mounts and put bombproof rubbers on 'em.
So you think your half way done now right? :roll: wrong! you have crossed maybe the 1/3 mark if your lucky...
Now before you start trying to bolt anything together or attempt to throw any new stuff in go to your local hardware store and buy 6 of every single nut and bolt pairs they have on the shelves :lol: just trust me on this one.
So on we go making things work where they are not supposed to work... So we use the 95 4wd gear shift because the 02 is using some pansy small linkage that didn’t impress me much and while we are down there we might as well shorten our rear drive shaft by 4 fingers width plus a karate chop palm width. (Now please let a professional do this and don’t try it with your sawzall ... any good machine shop or drive line specialist can do it for about 50 George W's) Seeing as how we are still underneath the beast this 02 t-case doesn't line up the way the 95 did so an aftermarket perch and padding was needed as well as a few new holes in my skid plate. Seeing as how we are here we might as well put the slave cylinder on and bleed it.
Ok now that we are done with that the rest is easy only because im sort of cheating and putting a carb on and scrapping that ole mpi crap but don’t worry you’ll make money on the deal I sold almost all of my 02 jeep stuff for twice as much as it cost for parts this way.
So you need a 258 intake, motorcraft 2150, headers (I used pacesetters that needed to be altered a little but nothing drastic), distributor, cap, rotor, ignition module, regulator for your alternator, electric fan (gonna need it if you don’t change the radiator out), coil, and some know how on how to do a little of this.
So long story short, :lol: , it was certainly worth it but as you can tell this adventure started in September of last year and is just now over. Would I dare venture off this cliff again :?: I say maybe I would.
Kletus
