Hello, long time lurker first time builder. I have pulled the trigger on swapping my 4.0 AW4 for a 5.3/4L60E combo in my 91 2 door 4x4 Jeep. I’ve already got started with pulling the drive train and have the 5.3 and 4L60E. I’m currently at work and will load some pictures during my next update. I appreciate all the guys who have already done this swap and the knowledge they have shared on here and other platforms. I appreciate it.
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91 2 door 5.3 V8 swap
- Thread starter BlueDevil
- Start date
I’ve read as many ls swap threads as I could find and wanted to document my build in hopes of helping others and to share in the frustrations of a V8 swap. Although now it seems like most things have been figured out.
A little history on the Jeep and what makes me so attached to it. This is my 1991 2 door Cherokee that my parents bought back in 1993. My mom drove it for a while and it eventually ended up being driven by my dad who was a carpenter. The back was mostly filled with tools as far back as I can remember. At some time it started leaking on the passenger side and water would accumulate in the floor board so dad took out most of the lower trim and carpet. Around 2010 it blew a freeze plug and so it sat. My dad passed in 2012 and I was in college and slowly started working to get it going again. It’s been an on and off project for me for the last 8 years or so as I finished college and then later grad school.
That brings us to today, where it was drivable, it has a 3.5” OME lift and I had reassembled the interior, minus the carpet, from various trips to the salvage yards over the years. 2 doors are not common in my area.
The color has always eluded me. No pint code on the door. From pictures I’ve always thought it was Spinnaker Blue Metallic. I found the color on the build sheet I got from chrystler and the paint code on the metal tag in the engine bay. Turns out it’s PB3 Intense Blue Pearl Coat.
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A little history on the Jeep and what makes me so attached to it. This is my 1991 2 door Cherokee that my parents bought back in 1993. My mom drove it for a while and it eventually ended up being driven by my dad who was a carpenter. The back was mostly filled with tools as far back as I can remember. At some time it started leaking on the passenger side and water would accumulate in the floor board so dad took out most of the lower trim and carpet. Around 2010 it blew a freeze plug and so it sat. My dad passed in 2012 and I was in college and slowly started working to get it going again. It’s been an on and off project for me for the last 8 years or so as I finished college and then later grad school.
That brings us to today, where it was drivable, it has a 3.5” OME lift and I had reassembled the interior, minus the carpet, from various trips to the salvage yards over the years. 2 doors are not common in my area.
The color has always eluded me. No pint code on the door. From pictures I’ve always thought it was Spinnaker Blue Metallic. I found the color on the build sheet I got from chrystler and the paint code on the metal tag in the engine bay. Turns out it’s PB3 Intense Blue Pearl Coat.
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The Jeep is mostly stock besides the OME lift and I’m running 31x10.5R15 on some wrangler wheels.I had a cheap junkyard/used lift on it back in my college days.
Stock 4.0
AW4 trans
NP231J with AA SYE kit
Flowmaster Super 40 muffler (way too loud now that I’m 33 haha)
Plans/intended use:
5.3/4L60E/241c drivetrain
Want to keep lift around 3.5-4.5” with long arm set up and maybe a 4 link in the rear.
Right now I’d love to make this my daily driver and do some tasteful upgrades for comfort while still keeping an old Cherokee on the road. I believe me and the wife are going to have it repainted the factory color as well.
I’ve been into the LS motors since high school. I originally went to a 2 year automotive technical school before going to a traditional 4 year college. I had a 95 V6 Camaro that I drove and wanted to LS swap it. After gathering a block, rotating assembly, heads and other parts I decided to scrap that idea. I can’t remember why now days.
The donor vehicle.
I came across a rolled 2004 Tahoe for sale on the marketplace for $1000. It was local so me and the wife went to check it out. I brought my battery and it started right up. The dash cluster was gone so mileage was a guess. The guy bought it from the insurance and wasn’t the owner when it was wrecked. I couldn’t hear any problems so I offered $800 and was the owner of a new Tahoe. Got it towed home and started the year down and part out to recoup what I could. After minimal effort I got back $700 of my $800 on the Tahoe and had the Tahoe out of the yard by the kiddos birthday party.
Stock 4.0
AW4 trans
NP231J with AA SYE kit
Flowmaster Super 40 muffler (way too loud now that I’m 33 haha)
Plans/intended use:
5.3/4L60E/241c drivetrain
Want to keep lift around 3.5-4.5” with long arm set up and maybe a 4 link in the rear.
Right now I’d love to make this my daily driver and do some tasteful upgrades for comfort while still keeping an old Cherokee on the road. I believe me and the wife are going to have it repainted the factory color as well.
I’ve been into the LS motors since high school. I originally went to a 2 year automotive technical school before going to a traditional 4 year college. I had a 95 V6 Camaro that I drove and wanted to LS swap it. After gathering a block, rotating assembly, heads and other parts I decided to scrap that idea. I can’t remember why now days.
The donor vehicle.
I came across a rolled 2004 Tahoe for sale on the marketplace for $1000. It was local so me and the wife went to check it out. I brought my battery and it started right up. The dash cluster was gone so mileage was a guess. The guy bought it from the insurance and wasn’t the owner when it was wrecked. I couldn’t hear any problems so I offered $800 and was the owner of a new Tahoe. Got it towed home and started the year down and part out to recoup what I could. After minimal effort I got back $700 of my $800 on the Tahoe and had the Tahoe out of the yard by the kiddos birthday party.
- Location
- In a strange land
I like where this is going.
All the details in one place makes things easier for those who follow.
All the details in one place makes things easier for those who follow.
Ol Blue
NAXJA Forum User
- Location
- Arvada, CO
Awesome, can't wait to follow along!
BrandonMag
NAXJA Forum User
- Location
- OR
I can see why you want to do an LS swap to this particular XJ: it's been in your life for quite a while and has some sentimental value. I think you will get some great enjoyment out of it once it's complete, and who knows? Maybe you'll pass it down to one your kids. Also, I like the color! ��
I've got a couple of questions:
What are you going to use for a radiator?
How are you going to route the exhaust?
What modifications will you need to make to bolt the 241 transfer case to the 4L60E?
TIA
I've got a couple of questions:
What are you going to use for a radiator?
How are you going to route the exhaust?
What modifications will you need to make to bolt the 241 transfer case to the 4L60E?
TIA
I do plan to pass it down to my daughter some day! To start with I’m going to use a stock XJ radiator. Several people have had luck with it and if it doesn’t work I’ll look into a griffin that’s close in spec to the Novak. Exhaust is yet to be determined based on how the engine sets in there but will use a Y pipe and route like factory out the back. I picked up a 241C and it bolts right up to my 4L60E. I plan to SYE the 241C as well.
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I’m going use the Chevy PCM as a stand alone. My Jeep is a 91 pre OBD2 so I think I could make my factory guage work I will probably go aftermarket.
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So last post I had the Chevy drive train out. I’ve got the motor cleaned up and painted Chevy orange. I thought it would contrast nicely against the blue. Honed the cylinders, new bearings, rings, gaskets etc. I did install a new cam from BTR, their stage 2 truck cam. I picked up an LS1 intake. I’ve been back and forth on using the truck vs car intake and whether I want to cut the hood or not. I am leaning towards not cutting and keeping the classic Cherokee look.
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Da XJ nut
NAXJA Member
- Location
- The Gump area
Very nice work so far. at least it will be all fresh and clean for the first few miles..... then time to take to the trails and find some stuff to run over and thru :viking:
yellowoctupus
NAXJA Forum User
- Location
- Silverdale, WA
Glad to see there's another 5.3 getting swapped, I'm starting to swap one into my '87 MJ.
