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LM4 5.3L and 4L60E swap into 2004 LJ

LBarr2002

LIFETIME
SUPPORTER
Today I checked the fit of the main skid. It's fine. The engine skid should be able to be adapted to work.

I ran the tcase and transmission vents up to the front.

I wasn't happy with the plastic coolant tank. I made a bracket for a cylinder tank on the other side which looks much better and allows more room for a bigger air filter on the other side.
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LBarr2002

LIFETIME
SUPPORTER
Big day today. Tripp and I pulled out the jeep harness we don't need (which required some changes from the way we wired the fuel pump and starter previously), and worked on gauges. Tripp has so much patience for this kind of stuff...

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And we ended with a run up town and fueled it up.

While Tripp was working on wiring and didn't need my help, I decided to check out the winch since the brake wasnt working. I took it apart and literally poured the brake pieces out of the drum. The snap ring had come off the end, so hopefully that fixes it. I also had to helicoil a couple holes.

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Now the bad news... last weekend I flex tested it and the tcase jumped out of 4low. I adjusted the cable but it still pops out...
 
No judging the cluster harness...we had to make several changes after the initial build... Including switching some of the fastons to ring terminals due to clearance and the added pull-up resistor harness (8.6k 1/4 watt....ish, tested with 9k on my decade box). Cluster was constructed using deutsch connectors for easy install/removal with full documention and every pin function labeled at the connector....I really do enjoy wiring...
 

LBarr2002

LIFETIME
SUPPORTER
I messed with the linkage today and it seemed ok in 4low... I guess for now I'm going to leave it and try to go ride a little at Gulches and see how it does.

I put the front bumper back on it today and put about 15 miles on it and hit the grocery store.
 

LBarr2002

LIFETIME
SUPPORTER
Did a little work this morning. Finished up vents, new ujoint in front shaft, bled the power steering, then headed over to Tripp's for a little bit. I think tonight I'm going to cut the throttle pedal down a little more. I can't get used to it where it is.
 

LBarr2002

LIFETIME
SUPPORTER
Spent the afternoon working on tieing the cross member into the skid. Also had an exhaust leak so pulled it down.

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When you read that you can't do this swap with a small lift (especially with a high pinion axle), one of the main issues is exhaust clearance to front driveshaft. I've had a little rub so decided to work that pipe while out.

I got interrupted by someone coming to buy the 4.0 so didn't finish it up tonight.
 
I can't keep the header collector bolts tight. Going to locktite them this time, but any other suggestions? Is it just the Chinesium bolts?
Locktite probably isn't going to work, you use heat to remove red locktite. You might need distorted thread nuts if new bolts doesn't fix it... I might would even try to tighten them when they are hot (expanded) and let them cool.
 
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