Full Size Jeep Network

ZJ 5.2 A-pipe


Cat runs right into the stock exhaust. You can see the hump in the a-pipe fits the crossmember exactly.

She's on the road. :rock: Just need to get the computer flashed (it's a 5.9 tune running the 5.2 right now) and take it to DEQ. Probably pass right now, but don't want to take a chance. It cranks a bit too long on start, not sure what's up there. Might just be the initial timing being different on the engine tune. The shifts seem to hang too late even under part throttle, not sure what's up there. Could be just a TV cable adjustment I guess.


Looks good! Needs some tires...

Good to hear. Do you have a 5.2 tune to put on it and see how it does?


Sent from my iPhone using Tapatalk

My neighbor is a Mopar tech and he's bringing the DRB home on Monday to try and connect and load a 5.2 tune onto it. I have a couple other options, but it's hard to find PCMs without the factory security.

Couldn't flash the 96 PCM. They locked a lot of them that first year due to overwrite problems.

Put in a replacement 5.2 computer (was running my extra 5.9 PCM), and this thing rips! Shifts a ton better, can feel the shift kit, it's very snappy. The exhaust note changed, too. Was sort of "whoosh" before. Can totally feel the extra 75 horse over stock. Sweet.

Can we get a followup report on how this has been running? I am thinking of doing a similar swap into my 78 Cherokee. Also, what did you use for a VSS on the transfer case? I looked through the posts but didn't find an answer. I may have missed it. Thanks

Sorry, missed your post!

Been running great. No codes from first fire. I was very surprised. Only thing that bothers me is the electric fuel pump I used has no check valve, and the WJ fuel filter is supposed to have one, but doesn't work worth a damn evidently. So I have long crank after it sits for a little bit. I have an XJ tank and fuel pump I might install, but I really wanted to keep the stock fuel gauge working. I'm going to try and dissasemble a gauge to see if I can integrate it into the cluster like the voltmeter install. Ot else build a custom tank that will house both the SJ sender and XJ pump.

I used a Dodge VSS that has both the electronic and cable drive. I believe it's all 88-93 Dakotas and the 91 YJ.It's the same piece Hesco uses with their 4.0 conversion for a YJ. I pulled a couple from 92 Dakotas at the yard, but you can buy them new from a parts store.



Some new BFGs today, 31 10.50 15s. I think it looks okay with the stock wheels. We'll see.








Now just need to fab front and rear bumpers, and a roof rack. Maybe weld-in rockers sometime.

Got the tailgate window working - every time - finally. Got new side tracks, replaced the wires that run through the tailgate pivot, routed them properly so they won't get squished again, replaced the rear switch, and cleaned the grounds and connectors. Works very well now. Whoohoo!

Have to order some carpet and I'd like to get the dash and seats covered with some gray or black.

Great job & nice rig, impressive work.

Paul That does look sweet, good choice on the tires. I do have that extra wheel, and cruise control thing. I spent the weekend putting my door panels back on.

Been working on the rig in bits and pieces. Bought all of the steel for a rear bumper/swingout and a roof rack. Just need more time in the days...

I did get it tinted today, it was a requirement from the wife. 35% all the way around. I like the way it looks but $400 was a bit hard to swallow.

Lookin' good. I tinted mine 35% when I moved back to Florida back in 98. Big, big difference for inside temps in the summer.

Good to hear. I had factory 20% tint on the rear of the XJ, wasn't sure about the heat impact with the 35%.

Cut out the dash to get rid of the post style radio, installed a single DIN CD player for Stacy. Bluetooth in an old classic, love it.

Beautiful Jeep I like the lift on it, not too much and not too low
has a nice lean and off road look to it

HowardT64 wrote:Its too bad the heater core couldn't be relocated somehow,
or redesigned. With all the smart ppl here I bet we could
figure something out. Heck I may even try my hand at it
1990 Grand Wagoneer
Duck Blind 2
360 V8
A/C P/S P/B P/W
peimar solar Equipped
55 watt Burner Fog Lights

I hope you must have tried your hand and become successful.. I think it is not so easy to relocate heater core..

bringing this back up for a question...do you have a pin out diagram for the 5.2/5.9?
You did an amazing job, looks GREAT!

Manimal70 wrote:bringing this back up for a question...do you have a pin out diagram for the 5.2/5.9?
You did an amazing job, looks GREAT!

I have a few manuals, for different years. I've downloaded them off some Dodge sites that have them in their FAQs.

Manimal70 wrote:bringing this back up for a question...do you have a pin out diagram for the 5.2/5.9?
You did an amazing job, looks GREAT!

This may get you started:



I downloaded the entire manual from jeepslimited.com for my donor (95 ZJ)

iirc Its mostly a 4 wire hookup if you keep the fuse/relay box from the donor (I'll look at my notes next time i'm in the garage...if I remember.)

1. hot from battery (big cable)
2. hot-start
3. hot-start+run
4. hot-run(/acc?)

Wire colors vary from year to year. Looking at the ignition switch in the wiring diagram will tell you which is which.

Gauges will also have to be wired in.

3 wires , plus fuel pump. Easy peasy.