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So, the vehicle in question is my '84 CJ7 ! I've had it for 2 great years now. Well unfortunately, earlier this month as I was on my way to the Jeep Jamboree at Silver Lake, I blew the motor. Now as much of a bummer as that is, I'm considering it a small blessing since this finally gives me the opportunity to drop in an engine that's more reliable than the AMC 304 I previously had! I'm a 19 year old college student and am planning to take my jeep to school (nearly 200 miles away) this fall. A mechanic friend of mine has been STRONGLY encouraging me to drop in a Chevy 5.3 and at the moment that's the direction I'm leaning towards. I guess what I need to know is: What the best swap kits are? What transmissions can be paired to a 5.3 and still fit my CJ? (I currently have a T-4 but am more than willing to switch to an automatic) And with no labor costs can it be done on a $5000 budget? Any other advice from Jeepers who've done this before would also be a huge help! Thanks!
I just finished swapping in a GM 5.7 TBI (87-95 truck) engine into my 77 CJ7 that previously had a 401/GM Turbo 400 . I removed the guts from the AMC 400 and installed them into a Chevrolet 400 case. Staying under 5K may be challenging. I would not bother adapting the T-4 to anything, much less a V8 rated at 285/325 HP/TQ. so factor in the expense of a new Transmission . An SM465 will bolt up to a 5.3 with minimal effort, but the small parts add up, like throwout bearing, clutch/PP assembly etc. The adapter between the tranny and tcase will likely be 3-500$ or more. Chances are you will need new driveshafts, or have your existing ones modified. You will need new motor mounts, I used M.O.R.E. mounts and am very happy with them, not sure if they have an option for the LS series in a CJ. I used a custom radiator from CGW/Brice Thomas, it was 450$ if I remember correctly. They cut a notch in their standard GM swap CJ radiator so as not to interfere with the power steering box lines. Without this mod I think it was 375$. There are cheaper and more expensive options, you get what you pay for. Also factor in money for exhaust work, I had a 2 into 1 built that exits in the stock location (drivers rear corner). I paid about 700$ for this, but I used a very expensive stainless muffler, and the guy I used is pricey, but he does good work. My biggest expense was not motor, or tranny, or anything big. It was the endless list of 5-50$ items from Oreilly/Autozone. Anyone who has restored an old vehicle knows what I am talking about, anyone who hasn't experienced this will probably not believe me and will have to find out for themselves, but I spent close to 2000$ on miscellaneous . It adds up fast.
Don't forget fuel system either. This was a major expense on my project and also a huge hassle. It needs to be done right as it is the heart of any fuel injected swap. Some folks will say "just slap a pump on the frame rail and run a return line and you're in business!!". External fuel pumps suck, and most of these folks wont admit that their fuel system is only reliable as long as the tank is at least half full. To do it right, with properly sized high pressure hard lines and fittings, an in tank pump with baffles/wells to prevent pump starvation, proper filtration etc. is expensive and a pain. Holley and Aeromotive both have retrofit in tank pump kits with built in baffles, but neither of these options is cheap, and you still have to run and route proper lines, filters, etc. Not trying to talk you out of a swap, just be aware that it is a lot of work, and a lot of expense to do it properly.
Just my opinion, which may be completely wrong.
Dave
Ultimately up to you but I saw two things in your post that caught my eye - 1 - $5k budget and 2 taking it as DD this fall...
Honestly, if I were you, I'd spend the time and money you have now making a AMC 304 , 360, 401 reliable, save some cash and next summer plan to come home and spend the whole summer with the swap then. Take your time and it'll be done much better. You'll have all the parts together and your full plan with much more than 2 months tops to get it done including procurement, like you'd have to do now...
Also not trying to discourage you from your ultimate goal, but what do you do when you can't take it to school this fall because it's still apart? You have a plan B already?
I didn't mean that to derail your plans / hopes - I just wanted to be sure you give all options a thought...
Swapping a new engine into a CJ does require a lot of "and then, and then..." and even more so with a computer controlled engine.
You're going to need someone who has done it to give good info and such, and get parts quickly to have a shot... I don't like being rushed personally with a job of that magnitude...
In my area a good running Rusty donor truck can be had for around a grand. I picked up a 6.0/4l60 for 800 with the ecu/ harness. If you go 4l60 then you need to off set the engine a bit and get a custom thinner drive shaft to clear the Transmission pan. 80s Chevy's had passenger drop t cases bolted to sm465. I can pull the complete setup from my local u pull it for less than $400. That's cheaper than the Dana 300 adapter. If you weld up some mounts yourself it may cost you 25-50$. I've heard camaro exhaust manifolds were easiest to hook up. Add a good radiator and some one piece axles and you're in it relatively cheap.
OP, have you thought about putting a AMC 258 i6 / 4.2l or even a 4.0 I6 back in it? Could be easily done for far less than $5k. The AMC 304 wasnt OEM on an 84
'85 CJ-7, 258/4.2L 6cyl. Bought new in 1985. Full cage, Warn 8274 winch, Ford 9" rear, front/rear Detroit Lockers w/4:88 R&P. T-5 tranny and 4:1 t'case. 33X12.50-15 BFG/AT, MSD ign, on board air---
I really appreciate all the great advice guys. Especially JR, don't worry you aren't derailing any plans, I asked because I wanted people's opinions on the matter and you definitely gave me that! I'm still really determined to do the 5.3 though, I have a lot of good, mechanically inclined people behind me on this that can help me if/when I get stuck. The one thing that really has me tripped up is the tranny though, if anyone knows anything on that one I'd be forever in your debt! https://www.jeep-cj.com/forums/images/smilies/notworthy.gif
I'd get a sm465 or you could even get a GM Turbo 400 with a passenger drop Transfer Case . That's probably the easiest route. I think if you do use a 5.3 with an older manual Transmission you need to use a spacer for the flywheel. I think they were pretty cheap though.
. It adds up fast. 
