I have had my 1997 2.5L Wrangler for about 17 years. I bought a Tacoma about a year ago and was originally going to pass the TJ along to a relative. Instead I decided that I should upgrade my engine to get more power and use it as a weekend warrior for my wife and I to cruise around and have fun in. I did a lot of research about the swap before I began. I originally considered doing an LS swap because it seemed popular but quickly realized (after seeing the estimate from Novak) that I should try a more economical route. This led me to look at the Magnum engines. I discovered that these engines had the POTENTIAL to be much easier and less costly so I dug right in. I prepped my garage and made note of my space. Don't underestimate this step. I hate tripping over stuff because I ran out of room.
97 TJ with a manual heart of a 5.9L Magnum
- Thread starter Jeepster11
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- 5.9 magnum
I picked up a Dodge Ram 1500 with 130k miles on it and it ran great. I did not want to completely rebuild the engine. I nicknamed my donor Bumble Beast (it was fantastically yellow) and started ripping its heart out. The guy that I bought Bumble Beast from said the engine was a 5.2. It wasn't until replacing the rear main seal until I realized that I had a 360 and not a 318. The rear main seal is slightly smaller on a 318 than one on a 360. Verify, verify, verify. These engines are pretty much identical but there are differences that will change the swap process.
It took me about 15 hours to pull my TJ harness and get all connections changed over so it will talk to my 5.9L. Like most other swappers have said, its really not too hard. You just have to think about the transition until you understand it. Probably my biggest hiccup was the ASD (Auto Shut Down). My TJ had the ASD running through the body harness but the Ram 1500 harness ran the ASD directly to the PDC (Power Distribution Center) I'm keeping my AX-15 transmission so it took me a little while to find a PCM for a manual Dodge 1500. I ended up buying one that came out of a 1998 Dodge Ram 1500 5.2L. It took me a little while also to find a flywheel that will work with my 5.9L. The 5.9L is externally balanced so I had to get a flywheel that was built for a 5.9 engine.
I listed my 2.5L engine for sale because you can get more $$ out of it if someone can hear it running. The guy that bought it from me said he would help me tear down and put the 5.9L back together. Deal. After ordering the Advanced Adapters motor mounts, I installed a 1.25" body lift per AAs recommendation. This took me about 4 hours to install
Welcome to the forum and the 5.9 TJ family.
I'm in the middle of rebuilding my TJ also. I had done a 5.2 swap back in 2005 and enjoyed it a lot. But due to a cracked head I was having overheating problems.
So I ended up buying a 5.9 core engine that I rebuilt. Then traded to someone who had a stroker 5.9 that wanted a stock 5.9. So I jumped at the deal and traded short blocks.
Look in my build thread in my sig for more information.
I'm in the middle of rebuilding my TJ also. I had done a 5.2 swap back in 2005 and enjoyed it a lot. But due to a cracked head I was having overheating problems.
So I ended up buying a 5.9 core engine that I rebuilt. Then traded to someone who had a stroker 5.9 that wanted a stock 5.9. So I jumped at the deal and traded short blocks.
Look in my build thread in my sig for more information.
Cleaning the engine was a lot more work than I thought. A 22 year old engine has had time to accumulate a lot of grease and grime. I discovered Autozone makes a good degreaser that breaks through the grease. I would highly recommend. Cover your internals and get ready to get dirty.
You can get your 5.2 PCM reprogrammed by someone like Flyin Ryan Performance. It is what a lot of people end up having to do when keeping the manual transmission. You can also reuse your auto transmission PCM and reprogram it for a manual transmission.
Ryan is a member on the forum as he offers tunes for Jeeps also.
@Flyin' Ryan Performance
Ryan is a member on the forum as he offers tunes for Jeeps also.
@Flyin' Ryan Performance
After about 20 hours of cleaning and painting and with the help of the guy that bought my 2.5L, the engine is looking nice. Right now I am waiting on my Flywheel and clutch to come in, then I can attach the engine and tranny and Tcase and start dry fitting it in the TJ. I have already removed the stock motor mounts with a angle grinder and reciprocating saw. My plan is to put the AA motor mounts where AA recommends mounting them, hold them in place with some beefy c-clams until I get the motor where I want it and then have a mobile welder burn them in place. Ideally I would like to be done by the end of the year but it seems like I still have a lot to figure out. ie power steering setup, there will be wiring harness adjustments, gas line fitment etc. Here we go.
Is it necessary to get the PCM programmed for the 5.9L to run? I was thinking that I would work to get the engine up and running and if it needed tuning to my Jeep and 5.9 specs then I would have it programmed.
The 5.2 PCM will allow the engine to run but it will be a little lean. Guys have ran them for testing and even daily driving but your missing out on power.
When you mount the engine mounts where AA recommends the transmission will sit a little forward of the stock position. It's not a problem and you just need to modify your shifter. I think there is a picture in my thread if not I can find one for you.
I had heard that I will be about 2 inches forward on my tranny. But, yes, a pic would be great to give me an understanding of how I should modify. I have a vice and propane torch and plan to heat and bend.
Since you are still gathering parts I would suggest you get a 1985-1998 Grand Cherokee power steering bracket and not use the Dodge brackets.
You reuse your stock PS pump & reservoir so no chasing down new lines. I have a GC bracket in all my parts some where. But you can but it on Ebay also.
Here is how wide it is with the Dodge PS brackets.
Here is a really good thread on doing the engine swap.
https://tinyurl.com/dtky5rhu
I'm still looking for a picture of the shifter.
You reuse your stock PS pump & reservoir so no chasing down new lines. I have a GC bracket in all my parts some where. But you can but it on Ebay also.
Here is how wide it is with the Dodge PS brackets.
Here is a really good thread on doing the engine swap.
https://tinyurl.com/dtky5rhu
I'm still looking for a picture of the shifter.
Here is one example but there is an easier way if I can find the picture.
Here is the way I would do it if I was using a manual transmission. This is easy & simple.
You just cut the shifter and then weld on a piece of flat stock the distance you need to move it back to the opening in the floorboard.
Let me know if I can be of anymore help.
Here is the way I would do it if I was using a manual transmission. This is easy & simple.
You just cut the shifter and then weld on a piece of flat stock the distance you need to move it back to the opening in the floorboard.
Let me know if I can be of anymore help.
Does the GC bracket really suck it in that much? Are we talking an inch or more like 3"? So I'm guessing that will change my serpentine belt. I still need to get a belt but have you confirmed which one works with the modified length of the GC bracket? I see you also lopped your accessory bracket in half to eliminate the A/C compressor bracket so our belts should be identical in length.Since you are still gathering parts I would suggest you get a 1985-1998 Grand Cherokee power steering bracket and not use the Dodge brackets.
You reuse your stock PS pump & reservoir so no chasing down new lines. I have a GC bracket in all my parts some where. But you can but it on Ebay also.
View attachment 284712
Here is how wide it is with the Dodge PS brackets.
View attachment 284713
Here is a really good thread on doing the engine swap.
https://tinyurl.com/dtky5rhu
I'm still looking for a picture of the shifter.
I've never measured one so I can't tell you how much it sucks it in but you wouldn't need any special serpentine belt as a stock GC belt would fit. When I did my swap I was also upgrading to a PSC pump and steering box so I could install hydro assist.
What I can tell you is that the Dodge brackets will fit BUT I had to trim my inner fenderwell because the pulley rubbed on it.
Yes I trimmed my bracket to and won't be running A/C for now. I bought a A/C delete bracket so I could run a A/C size belt but with the 6 Pack intake manifold it was easier to run without it.
Can't see the pics. Sorry I'm a newb. Should I go to one of your threads to see the pic?Here is one example but there is an easier way if I can find the picture.
Here is the way I would do it if I was using a manual transmission. This is easy & simple.
You just cut the shifter and then weld on a piece of flat stock the distance you need to move it back to the opening in the floorboard.
Let me know if I can be of anymore help.
I don't know why you can't see the pictures. I'll try to get some help from the admin.
@Chris do you know why or what is going on?
It's not a issue on your end. There is a problem with the pictures. I'll try reposting them later today.