So, deanschool was nice enough to put together the "mini-bible" for the magnum swap. I want to add to that though, so I've created a document that I will attempt to keep up to date as people add more information and as I learn more. Feel free to post info or PM me I can add it as needed. This is apply to swapping a 5.2L or 5.9L into a TJ, although I'm sure it will apply to YJ's and XJ's with the except of the PCM stuff as it will be OBDI
I have compiled an entire list of everything it took me to do the swap. I planned to do this from the beginning, and worked on this throughout. If something in it is incorrect, PLEASE let me know and I will change it/update it/etc. If I would have had this list in the first place, it would have saved me HOURS of research and returning random parts. Sorry the clutch information in inconclusive, I forgot to request the part numbers from the local mom/pop shop I got it from.
For the Master parts List
MASTER PARTS LIST
For this document in another form (has a lot of info, between this forum and the doc you should get a full feeling for what you need/etc)
DOCUMENT FORM
Short Version: The ZJ got totaled, I decided to go for a V8 swap in a TJ
(Skip to MY NEXT post):
Long Version:
To start off, the story is the ZJ was sitting in the driveway at my parent's house, and someone ran off the road and hit it. I may have been able to fix it and get a rebuilt title for it, but considering the amount of rust that was in it (floorboards were going to need patched this year, in addition to the rockers were completely gone), I decided to opt for fighting insurance to give me what it was worth. And, well, lets just say I came out "satisfied" with what insurance paid out to me for the ZJ, in addition to letting me keep it.
Right when the ZJ was totaled, I started my final semester/term for my master's, and was taking 4 classes while working...so I had no time to really mess with the Jeep anyways (which let me drag out the process with insurance...they hated me.)
I used my spare time to search for a replacement ZJ, but as I looked more and more, I thought about how I liked having a convertible so much. So, in came the idea of a TJ. I'm a fan of A/C and leather, in addition to all the other amenities that my ZJ spoiled me with, as well as the power of a 5.9L.
Thus came the thought of swapping a 5.9L magnum into the TJ. At the time, I didn't know it was pretty common. I quickly found a few people who had mentioned parts needed, etc. Before long, I was sold on the swap and wanting a Wrangler. I’d been wanting to do a larger project anyways, so this was a perfect fit.
I found a yellow (yea, it’s my favorite color…so what?) TJ in Georgia, about 8 hours away. My wife was 6 months pregnant (8 and a half as of writing this) and didn’t want to go with me (understandably). I had to go south for a vehicle…I refused to fight rust. This TJ has literally ZERO rust anywhere (even the cross member, etc are spotless). The downfall of it was that it was a 2.5L 4cyl and have 200K miles on it. The body was a little dinged/dented, but overall was in decent shape other than paint. No concerning leaks, no check engine lights, and everything worked on it. Plus, for the price, it was about as cheap as you can get a TJ with a hardtop (2 piece at that) and full doors. So, after agreeing on the price (the guy was more than helpful, and wanted to make sure if I drove that far that I was happy) I set up a time to get there Saturday afternoon and rented a Fiesta.
cameringo_20170409_142935 by Mitch McCoy, on Flickr
But, let's get started with the build!
I have compiled an entire list of everything it took me to do the swap. I planned to do this from the beginning, and worked on this throughout. If something in it is incorrect, PLEASE let me know and I will change it/update it/etc. If I would have had this list in the first place, it would have saved me HOURS of research and returning random parts. Sorry the clutch information in inconclusive, I forgot to request the part numbers from the local mom/pop shop I got it from.
For the Master parts List
MASTER PARTS LIST
For this document in another form (has a lot of info, between this forum and the doc you should get a full feeling for what you need/etc)
DOCUMENT FORM
Short Version: The ZJ got totaled, I decided to go for a V8 swap in a TJ
(Skip to MY NEXT post):
Long Version:
To start off, the story is the ZJ was sitting in the driveway at my parent's house, and someone ran off the road and hit it. I may have been able to fix it and get a rebuilt title for it, but considering the amount of rust that was in it (floorboards were going to need patched this year, in addition to the rockers were completely gone), I decided to opt for fighting insurance to give me what it was worth. And, well, lets just say I came out "satisfied" with what insurance paid out to me for the ZJ, in addition to letting me keep it.
Right when the ZJ was totaled, I started my final semester/term for my master's, and was taking 4 classes while working...so I had no time to really mess with the Jeep anyways (which let me drag out the process with insurance...they hated me.)
I used my spare time to search for a replacement ZJ, but as I looked more and more, I thought about how I liked having a convertible so much. So, in came the idea of a TJ. I'm a fan of A/C and leather, in addition to all the other amenities that my ZJ spoiled me with, as well as the power of a 5.9L.
Thus came the thought of swapping a 5.9L magnum into the TJ. At the time, I didn't know it was pretty common. I quickly found a few people who had mentioned parts needed, etc. Before long, I was sold on the swap and wanting a Wrangler. I’d been wanting to do a larger project anyways, so this was a perfect fit.
I found a yellow (yea, it’s my favorite color…so what?) TJ in Georgia, about 8 hours away. My wife was 6 months pregnant (8 and a half as of writing this) and didn’t want to go with me (understandably). I had to go south for a vehicle…I refused to fight rust. This TJ has literally ZERO rust anywhere (even the cross member, etc are spotless). The downfall of it was that it was a 2.5L 4cyl and have 200K miles on it. The body was a little dinged/dented, but overall was in decent shape other than paint. No concerning leaks, no check engine lights, and everything worked on it. Plus, for the price, it was about as cheap as you can get a TJ with a hardtop (2 piece at that) and full doors. So, after agreeing on the price (the guy was more than helpful, and wanted to make sure if I drove that far that I was happy) I set up a time to get there Saturday afternoon and rented a Fiesta.

But, let's get started with the build!