'01 XJ 2WD, 5.3L 4L60E Build
11-06-2013, 09:34 AM
#1
Newbie
Thread Starter
'01 XJ 2WD, 5.3L 4L60E Build
Documenting my 5.3L swap into an '01 2WD XJ.
Specs of build:
5.3L with 4L60E, remain 2WD
Keep Jeep AC Compressor—make custom brackets
Utilize GM P/S and Alternator
Novak engine mounts and headers
Picked up this XJ in OKC with an engine with a severe knock.
Out with the old
In with the new
Side clearance
Transmission mount:
I tried truck manifolds and LS3 Corvette manifolds. I cut the flanges off of them. I couldn’t get them to fit on the driver’s side. So, Novak to the rescue. With Novak mounts and headers, the engine and transmission were in. Next, I started on my A/C brackets. I wanted to replicate the base the original A/C compressor was mounted to. This:
So, I built this out of 3/8” aluminum and spacers:
I used a tensioner from an ’03 Dodge 4.7L. It has an idler wheel built into it. Final product looks like:
Next, I’m going to modify the GM alternator / P/S bracket. I’ll leave the P/S pump as is, and make some brackets to move and lower the alternator. I plan on shaving 3/8” off of each side of the original bracket so that a 3/8” plate can be placed behind and in front of it to holt the alternator.
Lots of details to still work out. I'm going to modify the XJ shifter as Frank Z did. Still have exhaust details to figure out.
Lots of thanks to the pioneers on NAXJA like Frank Z and Jeff 98XJ!
Specs of build:
5.3L with 4L60E, remain 2WD
Keep Jeep AC Compressor—make custom brackets
Utilize GM P/S and Alternator
Novak engine mounts and headers
Picked up this XJ in OKC with an engine with a severe knock.
Out with the old
In with the new
Side clearance
Transmission mount:
I tried truck manifolds and LS3 Corvette manifolds. I cut the flanges off of them. I couldn’t get them to fit on the driver’s side. So, Novak to the rescue. With Novak mounts and headers, the engine and transmission were in. Next, I started on my A/C brackets. I wanted to replicate the base the original A/C compressor was mounted to. This:
So, I built this out of 3/8” aluminum and spacers:
I used a tensioner from an ’03 Dodge 4.7L. It has an idler wheel built into it. Final product looks like:
Next, I’m going to modify the GM alternator / P/S bracket. I’ll leave the P/S pump as is, and make some brackets to move and lower the alternator. I plan on shaving 3/8” off of each side of the original bracket so that a 3/8” plate can be placed behind and in front of it to holt the alternator.
Lots of details to still work out. I'm going to modify the XJ shifter as Frank Z did. Still have exhaust details to figure out.
Lots of thanks to the pioneers on NAXJA like Frank Z and Jeff 98XJ!
11-22-2013, 11:13 AM
#5
Newbie
Thread Starter
More Progress
Got a little bit done last night
Closed the hood and the current brackets are definitely too tall. I’ll lower them about an inch and push them out about an inch.
Moved on to working on the shifter cable. I bought a trailblazer shift cable, but decided to give the stock XJ cable a try. I took the shift arm off of the 4L60E and flipped it so that it is pointing up.
Right now, the arm is pointing about 5°back when in park and about 5° forward and down when in 1st. I’ll cut up this arm so that it is about 45° back in park and 45° forward in 1st so the cable is pulling on it as perpendicular as possible.
I’ll make a bracket to hold the cable end in this location.
I think the 4L60E needs about 2.65” of cable travel, but the XJ shifter only gives about 1.88” of travel. I can shorten the 4L60E arm or increase the XJ arm at the shifter. I prefer to increase the XJ shifter arm so that I don’t lose leverage on the transmission side.
Finally, I’ll mark the shifter gate with the locations of each gear position and probably cut off the existing gate and weld on a new gate with new detents, the same as Frank did.
Closed the hood and the current brackets are definitely too tall. I’ll lower them about an inch and push them out about an inch.
Moved on to working on the shifter cable. I bought a trailblazer shift cable, but decided to give the stock XJ cable a try. I took the shift arm off of the 4L60E and flipped it so that it is pointing up.
Right now, the arm is pointing about 5°back when in park and about 5° forward and down when in 1st. I’ll cut up this arm so that it is about 45° back in park and 45° forward in 1st so the cable is pulling on it as perpendicular as possible.
I’ll make a bracket to hold the cable end in this location.
I think the 4L60E needs about 2.65” of cable travel, but the XJ shifter only gives about 1.88” of travel. I can shorten the 4L60E arm or increase the XJ arm at the shifter. I prefer to increase the XJ shifter arm so that I don’t lose leverage on the transmission side.
Finally, I’ll mark the shifter gate with the locations of each gear position and probably cut off the existing gate and weld on a new gate with new detents, the same as Frank did.
11-22-2013, 11:50 PM
#6
CF Veteran
Join Date: Feb 2010
Location: Missoula, MT
Posts: 3,353
Likes: 0
Received 1 Like
on
1 Post
Year: 1999
Model: Cherokee
Engine: Golen 4.6 Stroker, AFE Headers, 62mm TB, 24 LB Injectors, Brown Dog kit, HF Cat, 3" Exhaust
Straight to the point and lots of pictures... subscribed
Trending Topics
12-12-2013, 03:14 PM
#8
Newbie
Thread Starter
Worked more on the accessory brackets. I had the A/C and alternator brackets cut out on a waterjet, so they are more precise and look much nicer than when I cut them out on a bandsaw. I’ve had to re-do my A/C bracket because I’ve installed water pump spacers to get the W/P pulley to line up with the crank pulley; I used a car water pump.
Still have several spacers to make and other things to finish up on the A/C side of it. I'm ready to be done with these brackets! They're taking up so much time!
Still have several spacers to make and other things to finish up on the A/C side of it. I'm ready to be done with these brackets! They're taking up so much time!
The following users liked this post:
ODV_98XJ (07-15-2019)
Thread
Thread Starter
Forum
Replies
Last Post
The Aristocrat
Wanted
2
02-25-2017 01:17 AM
Raney120
Stock XJ Cherokee Tech. All XJ Non-modified/stock questions go here
22
10-16-2015 11:27 AM
sjm79902
Stock XJ Cherokee Tech. All XJ Non-modified/stock questions go here
2
09-30-2015 11:14 PM
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)