Engine swap comparison

[KingCarGuyZ]

All good things must come to an end, and after 330,000 miles the #2 cylinder on my 4.0 sounds like it's cracked and on its way out. Before I go out and stab another 4.0 in, I wanted to take a look around and compare some of the "standard" engine swaps done on TJ's below is what my first round of looking discovered:

I'm curious to see what people would do in my situation, I have about $2,500 tops to throw at the problem. The goal is reliable torque (and some HP) for a daily driver (A/C is a must) but we're not shooting for crazy numbers - something in the land off 300HP give or take. I'm pretty good with wiring and what not but I can only take the jeep down for about 4 days, so "take the engine out and build a stroker the right way" is kinda out of the option. I'm trying to avoid a substantial increase in "cost per miles" so diesels are fine, but I'm trying to avoid premium fuels. In a perfect world I would put a 200HP TDI in her and be happy - but theres not 6K on the table to do that right now. Really a cheap 87 octane stroker, or Magnum 5.9 are the main "high power" competitors.

Alternatively, I am trying to decide if it will be more cost/time affective to swap in a 100-200K 4.0 or do an in frame quick and dirty rebuild with new pistons, rods and bearings (probably lifters as well, as mine are noisy)

-Edit: fixed the table

 

[k1n3k]

OM606 has my vote. you can put a fully mechanical p-pump on an OM606. they're light too, a little lighter than the 4.0. plus its pretty easy to get 350-400hp from them. And adapter kits are readily available. AND its a inline 6 that can rev to the moon. AND they run smooth as heck. I'm also dumb and diesel swap things. 4 of my 5 samurai's have had diesels in them at one point or another. the TDI engines are neat but a OM606 is better.

 

[KingCarGuyZ]

OM606 has my vote. you can put a fully mechanical p-pump on an OM606. they're light too, a little lighter than the 4.0. plus its pretty easy to get 350-400hp from them. And adapter kits are readily available. AND its a inline 6 that can rev to the moon. AND they run smooth as heck. I'm also dumb and diesel swap things. 4 of my 5 samurai's have had diesels in them at one point or another. the TDI engines are neat but a OM606 is better. View attachment 636303

They’re great engines, and that was the original plan years ago but I’ve heard a hard time getting an engine for under 2K - never mind a swap done. How much do you average for yours?

 

[Wildman]

Since you have a older TJ if you wanted a V-8 you could do a Magnum 5.2 or 5.9 which with either you can build your own wiring harness. It's only about 19 wires you have to blend together between your TJ harness and the Magnum engine harness.

If you're set on a diesel swap then that isn't something I can help with.

Then there is a Hemi or LS swap also but they are more $$$$

 

[User4574]

All things being equal and only the piston being the issue, if it is only a piston you could do the dirty refresh and buy some time to let you save/plan for the swap you want to do vs. the swap you have to do. It *should* be pretty straightforward and easy enough to plan for downtime.

That much in miles I'd keep money to a minimum. Sounds like your biggest challenge is downtime and back on road.

 

[macleanflood]

Why swap? I'll bet if you threw pistons, rings and bearings and a bucky ball hone...new Felpro head gasket kit, studs and thread sealant... maybe a meling timing chain set and oil pump...you could have that back up in running in a weekend for less than $600.

-Mac

 

[KingCarGuyZ]

Since you have a older TJ if you wanted a V-8 you could do a Magnum 5.2 or 5.9 which with either you can build your own wiring harness. It's only about 19 wires you have to blend together between your TJ harness and the Magnum engine harness.

If you're set on a diesel swap then that isn't something I can help with.

Then there is a Hemi or LS swap also but they are more $$$$

I’m considering a 5.9 swap - how much did yours cost and about what are you getting for HP and fuel economy?

 

[KingCarGuyZ]

Why swap? I'll bet if you threw pistons, rings and bearings and a bucky ball hone...new Felpro head gasket kit, studs and thread sealant... maybe a meling timing chain set and oil pump...you could have that back up in running in a weekend for less than $600.

-Mac

Yeah, the problem is a new to me motor is also about $600 - so its down to what’s easier and better for the long run lol.

 

[Wildman]

I’m considering a 5.9 swap - how much did yours cost and about what are you getting for HP and fuel economy?

I did my 5.2 swap back in 2006 so prices aren't the same.

Dodge said the 5.9 made 245-265 HP & 330-360 TQ but many say they were under rated and I'd agree. As far as fuel economy goes with the 5.2 got what others with 4.0's were getting more or less. I say this because when we'd run a trail together and then fill up we'd take about the same amount of fuel.

https://www.jeepforum.com/threads/wrangler-magnum-v8-discussion.1365878/#replies

This is about the best Magnum swap thread I know about out there. And if you read through it you'll find guys who said they did their swaps for under $2K after selling off the donor rig and Jeep parts.

The HARD part now is that you can't find a low mileage Magnum V-8. And I wouldn't do a swap on anything with more than 100,000 miles without rebuilding it first.

What is your plan for the rest of the drivetrain? Automatic or manual?

If you were closer I could sell you a stroker kit for the 5.9 making it a 6.7... And a pair of old school EQ heads & a built 46RE transmission.... It's what came out of my TJ when the block cracked due to a FUCK UP on the machine shop part.
I've got a 5.7 Hemi and 545RFE in my TJ now... But I'd lucked out and found another 97 TJ with a Hemi swapped into it but had a bad transmission.

 

[5632]

I strongly recommend an LS.

 

[NashvilleTJ]

I strongly recommend an LS.

...for $2,500?

 

[Wildman]

I strongly recommend an LS.

Really??? Who'd have ever guessed that?? There are just as good platforms as your LS and unless you have an 03-06 TJ they are better IMO.

...for $2,500?

Not even CLOSE.... A Magnum swap could be done for that price as long as you're not rebuilding the engine/transmission... But I'd also worry that the OP would be back to having a worn out engine since most Magnum V-8's are going to have 250K miles or more on them.

 

[Apparition]

...for $2,500?

If you can find a good donor truck driveline for $1k or less there's a possibility.

 

[Wildman]

If you can find a good donor truck driveline for $1k or less there's a possibility.

Can you line that out price wise? I'm guessing you're saying us the GM t-case so you don't need an adapter? What about gauges? I still believe even if you had a free or close to free LS drivetrain it's going to be closer to $5K for a swap. But then I'm sure I can be proven wrong too.

 

[jeepguy03]

If you can find a good donor truck driveline for $1k or less there's a possibility.

You can certainly find the driveline and stuff for that price, but I think the expense really is in the mods needed to make the LS work in the TJ.

I guess my biggest question is at 300k miles, how is the rest of the Jeep? Is it in pretty decently maintained shape or is it a basket case that needs everything done to it? Would it be worth dropping a $5k engine in it or would a $600-700 used 4.0 be a better choice?

Unless you just HAD to have a V8 I'd probably be going the stroker route, since it is a bolt-in solution. Next would probably be a 5.9 Magnum freshened up before dropping it in. In the meantime if this thing needs to be back on the road quickly I'd be throwing another piston and rod in it while rebuilding the V8 or acquiring the stroker. I knew someone who did this and drove their Jeep (XJ with 280k) another 2 years with the 1 replaced piston and rod.

 

[Apparition]

Can you line that out price wise? I'm guessing you're saying us the GM t-case so you don't need an adapter? What about gauges? I still believe even if you had a free or close to free LS drivetrain it's going to be closer to $5K for a swap. But then I'm sure I can be proven wrong too.

Buy the adapter for $600 to use the tcase and get and OBD2 reader for your dash for $100. You’d have to be good at fab to get it done but it’s doable.

If you truly only have $2500 to spend I’d recommend finding a used 4.0l and forgetting swapping because any of them can get out of hand easy.

 

[MikeE024]

If you truly only have $2500 to spend I’d recommend finding a used 4.0l and forgetting swapping because any of them can get out of hand easy.

And if you can’t find a good deal on a used 4.0L, maybe consider S&J if you don’t trust your local rebuild options.

 

[glowell222]

If I was doing an engine swap, I would consider a GM Vortec 4200: Inline 6, crossflow head, mates up to a lot of different transmissions, including the AX15.

 

[Wildman]

Buy the adapter for $600 to use the tcase and get and OBD2 reader for your dash for $100. You’d have to be good at fab to get it done but it’s doable.

If you truly only have $2500 to spend I’d recommend finding a used 4.0l and forgetting swapping because any of them can get out of hand easy.

I'm still calling BS on it being done for $2500 or even close to that... And a OBS reader as your dash? Are you saying something like a ScanGauge? But OK I guess I'm wanting real gauges.

If I was doing an engine swap, I would consider a GM Vortec 4200: Inline 6, crossflow head, mates up to a lot of different transmissions, including the AX15.

For under $2500?

 

[glowell222]

I doubt any swaps could be done for under $5000--under $2500 is a hash-pipe dream. This engine is close enough physically to the 4.0 that it would be easier and a trans adapter would be unnecessary, plus the Vortec engines are fairly cheap. Call it $5k.