Well my jeep is a 1990 Jeep Cherokee Limited with the heavy (5,000 lbs) towing package (Dana 44 rear and trans cooler). It has the aw4 mated to the np242 t-case. I just bought it about 3 weeks ago for 800 dollars and at that time it had 292,800 miles on it. There was about six inches of oil in the air box and I was told that it took a quart of oil every 100 miles and ran rough at idle. So I bought it with the idea of rebuilding it as soon as I could. With the help of a friend I had it torn apart by the third night of owning it. It shows how good the design and quality of 4.0 is because even with obviously no maintenance and oil as thick as molasses (very little of it at that) that jeep stayed at a good even temp and ran, not to mention the fact that all parts were way within proper specs.
Anyway the following is a list of the parts and prices for my stroker
Block: original block bored .060 over-cost about 70 bucks for machine work
Crank: 258 crank out of 76 amc with 60,000 miles on it 100 dollars for the entire engine the crank came out of and 70 bucks to have it ground 10/10 (not because it needed it, but because I bought the rebuild kit from a friend that was not going to use it and new bearings would have been about the same price. Also had the snout cut to same length as stock 4.0 crank
Rods: Stock 4.0
Pistons/master rebuild kit: Cast aluminum .060 over. It was about 20 bucks to have the wrist pins pressed–these came in the rebuild kit I bought from my friend which came from flatlander racing it was about 380 bucks when he bought it they are about 475 now. It came with all needed seals, gaskets, pistons, cam, lifters, rings, wrist pins, oil pump, timing set (gears and chain), bearings and whatever else I’m forgetting
Cam: new stock
Pushrods: stock used a friend’s lower mileage rods.
Lifters: new stock
Timing set: new stock
Head/valves: ported and vale size increased to Chevy 2.02 Intake 1.60 exhaust (used Manley valves-bought from machinist 25 bucks) it was about $2.50 (2.50*6 intake and 6 exhaust) a hole to have the head cut for these valves. 3 angle valve job New Chevy valve guides. Used Vortec locks and retainers from machinist-25 bucks. Old stock rocker arms. New stock springs ---cost for all head work and parts was about 150 dollars
Thermostat 180 degree- cost…cheap enough that I don’t remember.
Intake: removed EGR stock throttle body (for the meantime) and stock injectors (also for the meantime)
Exhaust: stock manifold-ground down the nasty stock welds after the flange and removed the EGR New S pipe flows way better than stock straight pipe until high flow turbo muffler
Total Machine bill: 550 dollars –This includes cleaning of parts install of freeze plugs and pressing of wrist pins. Also includes the new head parts (valves and the like)
Total parts bill: around 450-500 for rebuild kit and new plugs fluids newer distributor from friend.
Total stroker cost was about 1000 dollars
