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06 TJ 4.0 into 00 XJ

Old 11-07-2016, 10:41 AM
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Old 11-15-2016, 12:39 PM
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Swapped is complete and successful. Only took myself two months taking my time and not knowing what I'm doing. If I can pull this off, I'm sure there are many of you out there than can improve some of my methods I went about things.

Here's the video of startup.
https://www.youtube.com/watch?v=RoL9...ature=youtu.be

There was a few things I had to hurdle over before I got there and it all revolves around cooling. I stated before that I had to figure out a lower radiator hose solution.

I went to the local parts store in town and talked to a guy there about my situation. After looking at all their hoses I couldn't find a good donor. We he called his supplier and ordered three hoses that he thought would work (Talk about awesome customer service!). Ended up with a Gates Vulco Flex Hose that fit the bill!

Part Number: 25532
Dimensions: 1 1/2 x 1 3/4" x 22"






The only other issue was coming up with a Fan Shroud for the mechanical fan and fan clutch clearance.

TJ Fan Clutch

I ended up pushing the radiator back 1" You can't go back anymore at all and I would have preferred 1/2" but the bend on the cross piece of the uni-body that the radiator mounts too is in the way to drill a hole. I just put the rubber grommets in the new two holes and re-drilled the top of the radiator support to fit the studs off the radiator. Radiator cap needed to be adjusted as well and cut out a little bit of the support to fit it properly. Viola! You now have all the space to fit your TJ fan clutch nicely.



XJ Fan Shroud


The next step was to mount the XJ fan shroud. Since its an XJ fan taking on a lot more unassisted without the stock E-Fan that is no longer there, a fan shroud is paramount to get the best cooling operation possible. (I will probably make side skirt that branches off the shroud to help create more air suction)

I cut off the tabs for the shroud off the radiator and welded them to a couple tabs that I then drilled a hole in to mount to the frame centered to the mechanical fan. Drilled holes on the radiator support for shroud bolts and Boom. Shroud mounted.





New Electric Fan

I also put a pusher fan on the front of radiator wired into the stock harness, so it kicks on like normal. Also I have an override switch for it but that's all in another video I made.






Thats it...No seriously.

-Get the motor brackets
-Keep TJ accessories (Didn't take the XJ route, that will warrant more work)
-Swap your fan onto the TJ clutch
-Make your radiator adjustments. (push it back, mount your shroud, get your flex hose)


I will make a more detailed step by step for my final official post. There's a few more minor things I didn't mention.

Last edited by KevinC506; 11-15-2016 at 12:46 PM.
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Old 11-15-2016, 01:02 PM
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Bravo. I've seen a few supercharger kits for these newer 4.0L's, so this may increase the variety of blower options, right? It was my understanding they couldn't be adapted to the older 4.0L because of the accessory mounts but I haven't looked that much more into it. Do you think you'll sell the mounts through IronMan4x4?
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Old 11-15-2016, 01:16 PM
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Originally Posted by alpine.adrenaline View Post
Bravo. I've seen a few supercharger kits for these newer 4.0L's, so this may increase the variety of blower options, right? It was my understanding they couldn't be adapted to the older 4.0L because of the accessory mounts but I haven't looked that much more into it. Do you think you'll sell the mounts through IronMan4x4?
I don't know too much about supercharger kits but whatever is out there for newer 4.0s would work. However they would probably be made to fit TJs WJs so some retrofitting may be in order for an XJ.

Yes these mounts are now for sale at ironman4x4. We have the drawings and can make them per request.
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Old 01-15-2017, 12:28 PM
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Here's my video covering this whole swap that I said I was gonna do.

Grab a beer and some scooby snacks.

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