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5.9 Magnum In The Cjtj

Discussion in 'Builds and Fabricators Forum' started by 1947cj2a, Dec 23, 2017.

  1. Dec 23, 2017
    1947cj2a

    1947cj2a Member

    PNW
    Joined:
    Nov 11, 2017
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    223
    I have owned my '98 TJ since well '98. Bought it as a stereo delete, rear carpet delete, 2.5L basic of the basics. Over the years the bigest changes were a Ford 9" in the rear, 35 spline shafts detroit locker, after that would be the Clayton Long arm kit and the last would be the HPD30 from a XJ all this was done about 10 years ago. So for the most part its stayed pretty stock.
    The little 2.5L has taken me to many places, drove it to Moab after that it was towed out there, it did the Continental Divide Trail ( Mexico to Canada) last year hauling my M416 trailer loaded down with gear and a tent a total of about 5000 miles 2800 of those was the CDT with about 80% off road.
    Over the last year, I started to look for a 5.2/5.9 Magnum engine to swap into it. I wanted to buy the whole truck, and I wanted the 5spd. I finally found one, a 2000 Dodge 2500 with the 5.9L 5spd 4x4. The truck was wrecked pretty bad in the front.

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    Its a snow wheeling machine, but always a little under powered!

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    Mid way through the CDT. I dont think you know what slow and hot is until you haul 1300lbs behind a 2.5L Jeep on 35's.

    The truck
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    I opted to remove the cab and box, and remove the whole engine combo out in one swoop.

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    Old faithfull

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    The whole combo came out for the first and last time. Its been a good engine and only 130k miles, it might find its way in another project in the near future.
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    Tearing down the new engine. I have some parts on order or so kind of waiting on them to show up before I can continue. After the holidays I will try to hunt down some parts that I need, like the oil dipstick, accessory bracket ( the impact cracked and broke the front of the original).
     
  2. Dec 23, 2017
    73 cj5

    73 cj5 Not ready for the junkyard yet

    Clinton, Mississippi
    Joined:
    Jan 10, 2014
    Messages:
    2,137
    These guys are the go to place for the 318 and 360 Magnum parts and what not.

    Hughes Engines
     
  3. Dec 23, 2017
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

    USA
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    Nice pic of ,what i assume is, Moab. Good luck with your swap. Keep us posted! Pics Pics Pics!
     
  4. Dec 23, 2017
    1947cj2a

    1947cj2a Member

    PNW
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    I ordered the Plenum gasket fix from Hughes, its in the mail.

    It is, its on the Hells Revenge trail
     
    73 cj5 likes this.
  5. Dec 24, 2017
    Mcruff

    Mcruff Earlycj5 Machinist

    Albertville, AL
    Joined:
    Sep 22, 2002
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    5,349
    The plenum repair kit is a must, gave me back all the power I had lost over the years due to the leaking intake. I did mine about 3 1/2 years ago now.
     
  6. Dec 27, 2017
    1947cj2a

    1947cj2a Member

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    Still waiting, on the biggest part. The new engine mounts from Advanced Adapters, but in the mean time have been staying busy organizing and getting more parts.
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    The NV4500 is quite larger, then even the old 2.5L
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    Had to modify and fix an old engine stand that was gifted to me. Next is to take the engine out side and give it a good washing.
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    Lots of parts waiting to be installed. on a side note, I opted to get the Remflex exhaust gaskets. I run these on my car now after blowing out many many NAPA/Felpro exhaust gaskets.
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    I was able to score a lot of new engine parts that got damaged from the local PullAPart. So the list seems to be getting smaller as far as stuff that is still needed.

    The next big thing will be the SYE kit for the Dodge 241 DLD, a clocking kit and a talk with JB conversions about getting the speed sensor on the transfercase (The Dodge one is on the rear differential). Also a talk with Novak about possibly using their cable shifter on for the 241.
     
  7. Dec 27, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
    Joined:
    Aug 18, 2014
    Messages:
    7,540
    I guess it's time for me to do mine if you two swear by it?
     
  8. Dec 27, 2017
    mike starck

    mike starck Member

    salem,oregon
    Joined:
    Jun 22, 2006
    Messages:
    762
    I have been using the Remflex gaskets for several years with excellent service. BTW they make them for the Dauntless motor and I have them on my 427 fe ford. mike
     
  9. Dec 27, 2017
    Greevesman

    Greevesman Member

    Napa, Ca
    Joined:
    Oct 12, 2014
    Messages:
    417
    I did the plenum repair kit in my truck several years ago. It stopped oil consumption and increased power. There are several how to do it threads on the internet.
     
    Focker likes this.
  10. Dec 27, 2017
    1947cj2a

    1947cj2a Member

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    I have never had to do the Plenum fix before, but I have heard a lot of first hand experiences with going through an engine and not doing it. I opted to get it out of the way while the engine is on a stand.

    They make a great product, I wish they were sold through my local parts store. It would have saved me a lot of headaches in the past.
     
    Focker likes this.
  11. Dec 31, 2017
    1947cj2a

    1947cj2a Member

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    I got the tcase apart, both of them. I will be able to use some parts from the 241 into the 231 and be able to reuse my 231 thus saving me some money for another SYE kit and more drivelines. It appears that the new engine will sit about 3" forward of where the old one sat but the NV4500 is about 4" longer, so I should be able to reuse my old drivelines.
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    241 on the left. I called JB conversions and got a full rebuild kit for the 231 and a new rear and front ou put yokes. The old ones had wear grooves in them
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    I will be using the 6 planetary gear from the 241. I was almost going to get away with using the input shaft as well but the pilot bearings are different. so I had to order one of those as well.
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    The engine is ready to go in, installed are new rear and front main seals, timing chain, oil pan gasket, valve cover gasket, thermostat, waterpump, plenum fix, everything got a good washing as well. the small parts went into he parts washer.
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    1" body lift got installed, this provides a little more clearince for the NV4500 and engine. This means that I will be taking about 1" of lift from the springs. Luckily I have a couple of sets of JK springs and shocks. I will have to play around a bit to see what I come up with.
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    Passenger side engine mount and up control arm bracket cut off and sanded smooth, after I blew the metal sendings away I took the pressure washer to the engine bay and gave it a good cleaning as well
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    Drivers side, I couldnt get my grinder close enough because of the metal lines but I got most of the old mount off.

    Monday or so I should be able to weld in the new engine mounts, then hopefully set the engine in and see about the transmission mount and exhaust and of course the wiring. but really those are the three big things left. engine mounts shouldnt take too long, but I have a feeling I will be fussing around with the exhaust and trying to make the wiring as neat as possible.
     
    47v6 likes this.
  12. Dec 31, 2017
    Focker

    Focker That's a terrible idea...What time? Staff Member

    WA
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    What!? No pics of this? :banghead:

    Looks good. (y)
     
  13. Dec 31, 2017
    1947cj2a

    1947cj2a Member

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    Haha,
    yeah sorry I got caught up in the reassembly. its actually a supper simple install. The only thing that changes is the plenum plate and gasket.
    The kit is nice and complete the instructions are clear.
    Kit included, new hose from manifold to pump, new O ring for the pump to heater core tube, new gaskets for the intake on the heads, new gasket for the engine deck, and all new fasteners. Even intake manifold fasteners and they appear to be correct mopar ones and not some randoms. Over all very happy with what you get.
     
    Focker likes this.
  14. Jan 13, 2018
    1947cj2a

    1947cj2a Member

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    Last Friday I finally received the new engine mounts from AA. there were some small issues with the rubber isolotors. It was solved rather quickly by removing a washer and switching from a nylock to a crushed nut after confirming with AA that everything else was correct. Still waiting on the NP231 rebuild kit from JB conversions before I can finalize the transmission location. That should be in on Monday. Unfortunately I have to go to China on the 17th of this month so I more then likely will not be finish this up until I get back in a couple of weeks.

    [​IMG]
    Engine mounts in and painted. circled in red is the area that needs to be notched to clear the exhaust manifold. If you were to use the center dump manifolds this will be a none issue. I decided to save the money and trim the pinch seam on the tub.

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    Engine finally in. Also the inner fender needs to be trimed right below the windshield water bottle where the rubber fender skirt starts to clear the power steering pump

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    New 3 core aluminum radiator from Champion radiators. This is a direct bolt in and it excepts the factory 4.0L TJ fan shroud. I was able to get one pretty cheap from the local yard.

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    I swear it gets put back together, it might even do something.

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    Labeling and tracing wires helped out a lot. I also have a TJ FSM and was able to find one for a 2000 dodge truck, so it helped a lot. From the TJ harness I am only using the fuel pump, speed sensor and the reverse lights. Everything else is the Dodge. some splicing was required.
    [​IMG]

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    New wiring harness installed! I can now start to run the new starter wire and start connecting my grounds. there is a lot of grounds...

    I might be able to test the harness before the NP231 is back together. If the harness is all good. I can start on the exhaust and finalizing the transmission mount. after that is making a new transmission hump cover and heating and bending the transmission shifter to fit.
     
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  15. Jan 14, 2018
    jeepstar

    jeepstar Well-Known Member 2024 Sponsor 2023 Sponsor 2022 Sponsor

    Sheboygan
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    Very nice job!
     
  16. Jan 14, 2018
    tarry99

    tarry99 Member

    Northern California
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    Looks Good!
     
  17. Jan 15, 2018
    1947cj2a

    1947cj2a Member

    PNW
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    Well it runs!!! short video below.

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    The clearance for the power steering pump on the inner fender
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    Its starting to look like something. will have to pay around with the hoses a bit. I am leaving the front off for now until the exhaust is finalized as I have an upper control arm that might need to be moved around. Its much easier with out the front clip to slid that thing in and out.



    It runs, right off the bat.
     
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  18. Jan 15, 2018
    47v6

    47v6 junk wrecker! 2023 Sponsor 2022 Sponsor

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    This is killer!
     
  19. Jan 15, 2018
    melvinm

    melvinm Member

    Arvada Co. 80003
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    I like the Dodge Car in the back Ground .

    Is that A 1966 Dodge with the 426 Hemi Engine ?
     
  20. Jan 15, 2018
    1947cj2a

    1947cj2a Member

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    It is, started life as a slant six three on the tree. Its the base model, below the delux. factory, heater delete, stereo delete, cig lighter delete, day time rear view mirror only. it has only one option the two speed windshield wiper motor.

    I then got a 383 4spd for it, and then i fell into a '68-69 426 long block. so its a 426 4spd with the dana 60.
     
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