So in order to run the newer style radiator setup (87 and newer), the radiator support has to be modified to accommodate for the larger radiator.

Dealing with this right now on my 86 MJ project and figured i'd shed some pics and info to potentially help others who may do this swap at some point.

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Old 86 setup on left, newer style 95 on right, don't mind the damage


new style support on the left and old style support on the right
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the old style support curves forward from the mounting holes while the new style is straight across. Just cut away the curve forward leaving it running straight across. In time i will cap the exposed cavity to also give it more strength.

 

then cutout (2) 2.75" x 4" pieces of sheet metal (mine are 18 gauge) and drilled the mounting holes to match the newer style radiator support.




view from the inside of the engine bay at the underside of the "new bracket"

I'll get some hardware, probably some 1/4-20 bolts and weld a nut to the underside of the mounting bracket holes.

then its welding the brackets to the existing support. I'll update as i make more progress.

 

mounting plates welded in and the new radiator support is mounted

 

Sorry to resurrect an old thread of yours but I am doing this same swap in my 86 Cherokee. After your made the necessary cuts and welds, what else was done before you were ready to drop in? My new radiator is not lining up at all was wonder if you have some pics of you dropping it in ??!

 

Are you trying to put in the 4.o radiator?

 

yes. It’s an aluminum radiator for 91 and up. Did you change anything with the lower support/crossmember?

I am currently doing a SBC350 swap in my 86. I made the mods for the upper support but can’t seem to get the radiator to sit in correctly.

 

Yes, I put a flat piece of steel in and then drilled two holes for the lower bushings for the radiator mount. Fairly simple and can be done without welding if you need to. The hard part thouigh was the hood catch. I had to change over to the 4.0 cross member and catches

 

I like that idea and sounds pretty simple. Do you want have any pics of that setup?

and for the hood latch, why did you have to change the lower crossmember to fit it? Did you use the old hood?

 

I have some pics somewhere. It was because of the hood latch. The spike would have been in the radiator

 

Gotcha! Once I can get this radiator fit, then I guess I will have to fit that next lol

 

Sorry for catching this soo late. What i didn't include in this setup was actually exactly what 4.3xj was mentioning. The A-member of the frame is also different! This can be remedied in multiple ways, ive seen it done a couple times where an A-member from the 87+ XJ/MJ was removed from a donor and then welded back into their 86 project. A bit entailed with drilling out plug welds and basically dissecting the front end of both donor and project to have that original finish. But by far the easiest solution would be to run a piece of flat stock steel from frame end-end and drill out 2 radiator bushing mounts for the posts that come off the bottom of the rad. As mentioned above you could zip-screw this metal in or weld it in place. I don't have a picture of my setup anymore but i went the flat metal strip route and welded the ends in. Also fwiw i defaulted to hood pins on the project i based this how-to on.

The overall build thread is still on here as well:
https://www.cherokeeforum.com/f46/19...167502/index2/

 

saving this!