3 inch all the way back is tight with stock style tank and suspension. With your setup, probably will just have to try and see if you can make it fit.
I do my own exhaust. I buy mandrel bends from Summit , cut the bends I want and butt weld them together. Muffler shop benders have a hard time getting bends close enough together sometimes to get in and out of tight spots. Besides, finding an old school muffler shop with a bender AND a guy who gives a shit is getting harder and harder. There was one guy around here that was great, but he retired 10 years ago and nobody took his place.
On a side note, people can get all bound up about mandrel vs 'crush' bend. I really doubt it matters much performance wise. I use mandrel because they fit together nice as long as you cut them square. The diameter stays pretty consistent through the whole bend. Makes butt welds easy to do.
Plans at this point are Stainless Steel all the way back and I have kits in 2.5" and 3". The only thing I haven't bought yet is a muffler as I was waiting to see how much room I had to fit one in. Hoping I can tack them together and then get it welded together.
Great info guys. Thank you. I will concur on the electric fan use. I thought I would be a cool kid and put and electric fan in a CJ I had once and it was NOT as efficient as the stock fan WITH shroud. So I plan to use the ZJ fan and the internet tells me I can use a 4.O shroud with it. The wiring, I have been scouring the internet and found the pin outs for the donor, TJ and Durango ECM. I think it's just gonna come down to me tearing into it and then once I get a idea of what is going on I will have more definitive questions. One disappointment is that the ZJ I bought was supposed to be a 96' but no it's a 94'.
Just make sure you get a newer wiring harness to help out with the wiring. If you are going to use a PCM from a 2001 Durango I would also get the engine wiring harness from the donor Durango. You can use a older block as long as you retain the emissions equipment from the newer donor vehicle.
Yes I get that you might not have a smog check where you live and all that . But Federal EPA laws still apply even if they are not being checked. If you do a engine swap and then 3-6 years down the road decide to sell your TJ if it isn't emissions legal technically you are not allowed to sell it. I know for some none of this matter I'm just suggesting to make life easier.
I had the engine set where Advanced Adapters suggests so I have to use a electric fan. I was running a brass core and a Flex-A-Lite Black Magic 15" fan and a Spal fan controller.
As PR said is you move the engine mounts back just a little you can run the ZJ fan & fan clutch with a TJ 4.0 shroud.
For radiator hoses these seem to have worked for others so I wrote the part#'s down.
Lower radiator hose- Gates# 22287 or Dayco# D71954
Upper radiator hose- Gates# 20983 or Dayco# 70480
The upper one you can just use a ribbed hose but if you are wanting to run the A/C compressor I've read that the molded hose seems to fit better.
A member over on the JF forum is in the middle of a V-8 swap and just figured out that 1992-93 Dodge Dakota 5.2 manifolds casting numbers are 53006619 drivers side and 53006618 passenger side. They measure 2 1/8 compared the the 2002 manifolds that measure 1 7/8.
I started a notebook with all this information written down inside it. If it doesn't help me out it might help someone else out at some point.
There is a 187 page discussion on the V-8 swap over on JF forum. It's long but a good read.
https://tinyurl.com/ybcekogv