5.2 Magnum Swap Part 22: Brakes and Wiring

by ThreeThirdsFab
November 24, 2015
In The Shop
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Welcome to part 22 of our 5.2 magnum swap, follow along as we swap a 5.2 magnum from a 1993 ZJ into our 2004 4.0 TTB WJ. With the long Thanksgiving weekend quickly approaching we have been spending some long nights in the shop getting it ready to finally go out.

Read The Rest
Part 1: It’s Finally Happening
Part 2: Out With the Old
Part 3: The Last of the Stock Components
Part 4: All About Brakes
Part 5: Pulling the 5.2 (time lapse)
Part 6: The Test Fit
Part 7: Cutting and (not) Fitting
Part 8: Broken and Upgraded Parts
Part 9: Leaky Plenum Gasket
Part 10: Side Projects and Summer Fun
Part 11: Setting the Motor
Part 12: Custom Exhaust & Driveline
Part 13: Cutting and Rebuilding
Part 14: Giant Radiator in a Little Jeep
Part 15: Custom Tube Bumper
Part 16: Driveshafts
Part 17: A Real Firewall
Part 18: Starting Final Assembly
Part 19: Extending The Engine Cage
Part 20: Still Assembling
Part 21: It Lives
Part 22: Brakes and Wiring

Brakes and Wiring

This week we finished up the interior wiring, ran brake lines, and started the last of the desert prep which included bolting up the rear drive shaft, running the cables for the new intercom and discovering the need for an unexpected rear shock rebuild.

When we removed the rear shocks to check for drive shaft clearance we found our FOA Coilovers were blown and the oil was pretty burnt. We knew this was coming since it had been over 1,000 miles since our last rebuild, but we were hoping to be able to squeeze one more trip out of them. Not the case. A rebuild kit was rush ordered and we will be rebuilding them Wednesday night right before it goes on the trailer.

Aside from the shocks, everything else is coming along smoothly. The new brake lines are a combination of stock WJ lines and new zinc plated 3/16″ lines from Allstar Performance (ALL48040). The rears run through a CNC Brake 888 Pressure Switch to give us brake lights before heading out back to the axle, and the front splits right by the master cylinder, then runs to each side.

Updating the Wiring

With brakes done we turned our attention to the interior. Over the years we have slowly added new switches, circuits, and relays to the Jeep. These new circuits were typically placed wherever we could find room. This made running new wires fast, but left the interior a mess of random wires and relays. This time around we tore out all of our old circuits and ran new wires for everything. Now our entire electrical system is conveniently located under the dash. It looks a little unorganized, but we don’t want to tape everything up until we get a full weekend of testing in.

With the wiring completed we cut a hole for our new RRP510 Pro-Series Intercom from Rugged Radios and installed the dash and center console.

What’s Next

This week will see a shock rebuild, brake bleeding, and whatever else it takes to get it out to the desert. After 5 and a half months of work we will be driving onto the trailer Wednesday night just in time for Thanksgiving in Ocotillo Wells.

Don’t forget to check back next Tuesday for updates.