Build Thread - 89 4X4 2.9L to 4.0L Swap

[rummblindohcv8]

Another 2.9L to 4.0 swap.

I have been reading about so many others 2.9 to 4.0 swaps, so I figured I would start this thread and try to document mine from start to finish.

Build truck: 89' 4X4 Ranger extended cab with ~270k miles. Currently has a 2.9L and Mitsubishi 5spd, Dana 28 TTB front axle and 7.5" rear axle.

Reading through the forums it seems that the only way to do this swap is to get a donor vehicle... so I did.
Donor truck: 93' 4X4 with ~167k miles. Bought it for the 4.0L, Mazda 5spd, Dana35 front axle and 8.8" rear axle.

Stay tuned...

 

[rummblindohcv8]

Pictures of the 89' and the 93' Rangers.

 

[dangerranger83]

I would just drive the donar, looks to nice to part out.

 

[rummblindohcv8]

I would just drive the donar, looks to nice to part out.

Yeah, I thought about it when I went to buy the donor truck, I was even convinced that I might end up with two project trucks. That was up to the point when I saw the frame rails. The rust and corrosion were to much to repair.

 

[rummblindohcv8]

So I took advantage of the warm day on Saturday to finish (I think) pulling parts of the donor truck and loading it up for the scrap yard (see pic).

Parts pulled from the 93' donor:
4.0L motor w/ engine harness
Mazda 5spd
BW1354 Auto T-case
Complete dana 35 front axle
8.8" rear axle
Both front and rear drive shafts
Fuel tank w/ sender
Radiator
Underhood harness

I was also lucky enough to score a bunch of spares when I picked up the donor, including a spare BW1354 auto T-case, another 8.8" axle, everything for another complete dana35, spare drive shafts.

All in all, I think I have everything to complete the 4.0 swap successfully. Well except the electrical, which I am 90% confident on. Although the only thing I haven't pulled is the dash harness.