I have a 1989YJ 4.2 5spd manual transmission and I purchased a 1991 Cherokee with a 4.0HO 5spd manual transmission. The question I have is can I take the engine, transmission and transfer case out of Cherokee and put it into my YJ? And can I take the gas tank-sending unit out of the Cherokee and put it in my YJ tank? I have the entire Cherokee.

I'm not sure what direction to go in? To change out the entire thing? or go with the 4.0 head change out on my 4.2? Which is best and which is easier?

Any help from someone who has done this in the past would be appreciated.

Thanks,

Joesphelk

Either one can be a pain in the <img src="/forums/images/graemlins/butwiggle.gif" alt="" />. Have you ever done a motor swap? Are you good with electrical?

I have done direct change outs of engines and transmission but not when major electrical is involved? I also have dealer service manuals on both Jeeps that I purchased just for this project. I no it would be smart of me to sell my 89YJ and just purchase a newer one with a 4.0 in it but I like my Jeep and want to hang on to it.

You are going to need to splice the 2 electrical systems togther in order for the gauges and computer. Either way will be a difficult electrical setup.
The cherokee and YJ tanks are incompatable.

Thanks,

I haven't started the project yet and i was wondering if the motor, transfer case and transmition are the same lenght in th eCherokee or am I going to need to move my motor mounts and or shorten or length drive line and so on?

It's going to be close, but not exact. What transfer case does the Cherokee have? You might want to stick with the 231 in the jeep and cannibalize the Cherokee transfer case.

I'm not sure about the model of transfer case? I was thinking of reusing the stock one out of my 89 and also replacing the clutch and the rest of the usual stuff related with the clutch while everything is out in the garage. About the sending unit? Can I get a 19-gallon tank like they use in the 91 Jeep Sierra and put it in my 89 without very much trouble?
I Think I will have plenty of more questions when I get into the project. Thanks for your help and this is the best Jeep website I have found, all the other websites IÆve asked questions on nobody would answer back or they donÆt have the knowledge to answer back.

Thanks again

89 YJ's came with a 20 gallon tank as an option on most models. To swap from 16 to 20 I think you must change skids too.
Some years had the same tanks (20 gal) and the 16 gal ones had a device in the top that would only allow 3/4 of a tank of fuel. It was fairly easy to remove the device.
Big Jim <img src="/forums/images/graemlins/pfft.gif" alt="" />

You should be able to get the skid plate and the gas tank from a 91 to fit on the 89. You'll have to do some wire adding. The 89 doesn't have an in-tank pump.

Yhe best site for 4.0 swap info. http://www.cjoffroad.com/forums/forum.asp?FORUM_ID=24

Yes it's geared mainly do CJ's but 99% of the info there is applicable to your YJ.