I'm working on a 4BT swap into my 1994 Jeep Wrangler YJ. I use this vehicle as my daily driver and love the open air driving. For the past 10 years, I've toyed with the idea of building a Jeep Wrangler that suits me. With the rising costs of gasoline and the pathetic fuel mileage the Jeep was getting. I began searching for alternative engines. My goal was to do a cost-efficient build and acheive the best fuel mileage I can get. I stumbled accross someone else who swapped in a Cummins Turbo Diesel. I was hooked. I began searching everywhere I could for information. And, I eventually subscribed to the Yahoo groups. Then, I joined here when it moved.
This thread has been almost like a journal of my build. I hope others considering their projects can use it when planning their build. It's kind of my exchange to the 4BT community for the information I've received from them. The swap, for me, wasn't just tossing in another engine and transmission. I also had to upgrade the drivetrain components to match. Each of those components was yet another swap itself I had to acquire information for and consider how they would perform together.
With all of that information floating around. It was easy to lose or forget it. I ended up making what I call my "Build Bible". It's a binder with partitions labeled "Donors, Engine, Transmission, Transfer Case, Front Axle, Rear Axle, Brakes and Other". All of the information with regards to each conmponent swap I could find was printed and organized into their repective sections. It was invaluable while I was working on multiple swaps and trying to keep everything straight.
I've also tried to include some of costs involved. It's easy for me to forget how every little thing adds up. I've seen more than a few guys on here and other places tell people to "Take those costs and double them". That is not the case here. I think I allowed $3500.00 for the swap. My costs are over double that and still going.
The build-up is complete. So, I'll post up my test driving experiences, fuel mileages, and maintenance history. My goal here is to give anyone interested a complete up-to-date account of my 4BT experience. So here goes!