2wd Xj to 4wd

Huntjess

I have a 1995 2wd xj with the AX15 manual. I also have a 1996 4x4 xj with the AW4 automatic. What do I need to take the transfer case from the automatic and put it on the manual?

Skyler-At-Novak

Hey,

The few key things I'm aware of that you'll need for this is on your AX15 the mainshaft and 2wd tailhousing will need to both be swapped for a 4wd one. You'll also have to be sure you have the correct input gear in your transfer case. The AX15 mainshaft is a 23 spline and I can't say for sure what spline your current transfer case has since the AW4 had both the 21 and 23 spline output.

I'm imagining you'll have to swap your front axle as well. And I'd think new drivelines as well since the transmission length will be different, they might work but that would be something you'll have to measure out.

You'll have swap over the shift linkage from the 96 xj into the other one as well.

I might be missing something hopefully some other forum members have some insight on this.

corkeh

You'll need the tailshaft and the 4wd rear housing to convert your ax15 to 4wd, and after all that you might be money ahead to just source a 4wd ax15 to begin with.

Driveshafts will be different lengths with the automatic and manual transmissions.

Front axle will be easy enough since the 2wd version is essentially a dummy front axle with the same mounting points. Just make sure it's the same ratio with the rear axle, or just swap both of them

Overall it's possible to do it with what you currently have and affordable if you manage to find some cheap used parts, but your goal with the manual swap is control, then it's entirely possible to convert your AW4 to manual shift. However, if you want the feel of a manual transmission, there's no substitute.