Got the donor for the 4.0 swap. Please show me links-

[red89yj]

Just picked up a 94 cherokee 4x2 "country" edition with the 4.0 and 4-speed auto for $500 today. This will be the donor for my 4.0 swap. Drove it home, runs awesome and all that good stuff. I posted on the cherokee forum already looking for info but coming from the YJ forum, i feel like there might be little responses.

A N Y W A Y. . . I hate to be one of those people starting a 4.0 swap thread, but Search isnt answering my questions, so im hoping i can be pointed in the right direction by my fellow YJ'ers.

Ideally, I would love to be able to drop the motor and transmission from the XJ into the YJ, but being that its a 4x2 donor, im starting to worry that the tcase wont bolt up. PLEASE TELL ME THAT AINT SO!!! I'd love to have the overdrive. If its impossible, its not too much of a loss.

Anyway im not gonna ask for everyone to reply with their own version of the steps in swapping, but ANY direction would be much appreciated. some of the websites just arent thorough enough for my mech. ability. I NEED MORE LINKS!

At most times, i just say to myself "If its wired or connected or comes from under the hood, remove it and stuff it, disconnecting only when absolutly necessary." I know that there is so much more to it than that, but i feel like im in a better position than most people who have done this swap, being that i have EVERYTHING at my fingertips. (Except the front-mount cps assembly, if i need to bolt up to my TF-999, but ill get that if its needed)

Thanks everyone- I hope I can get some help.

Rich

 

[Bounty__Hunter]

Great choice on using the AW4 auto, it's a good reliable transmission and has an OD 4th gear.

You won't be able to bolt it up to your transfer case without either unbolting the 2wd tailhousing or using an adapter from a 4wd XJ, not sure how that transmission is set up. You will need a different input shaft for your transfer case as the AW4 is 23spline.

You'll need to redrill the bolt pattern in either the NP231 or the AW4, as the XJ transfer case hangs down lower and you'll need to clock the transfer case up in your jeep.

Here's an entire forum dedicated to the 4.2L to 4.0L swap: http://www.cjoffroad.com/forums/forum.asp?FORUM_ID=24

I'm parting out a '93 XJ 4wd, I'll take a look at the end of the AW4 and see just what you'll need to do.

 

[red89yj]

yeah that would be great bounty. im waiting for a reply from Novak Conv.'s tech dept (apparently they answer all emails) but ill end up calling them anyway just to make sure of what needs to be done. according to their site, the input shaft on the t-case is 23 spline also? i dont know for sure, but thats what the table said on the novak site. I'll definitely re-drill if i have to, only because the clocking ring can add ~1" to the driveline, and its already gonna be longer than the 4.2/999 combo, even with the Fixed Yoke kit.

 

[Bounty__Hunter]

I don't know if the 999 and the AW4 have identical outputs, you'll have to swap the transmission input if they don't.

A friend of mine just put an AW4 in his TJ, and had to get the TCU for the AW4 to work with the TJ's computer. Don't forget that the AW4 uses it's own 'puter, called a Transmission Control Unit (TCU).

 

[red89yj]

shouldnt be a problem as the donor cherokee that im pulling the motor from is mated up to the aw4, so it does have it.

 

[red89yj]

after days of research, i decided to go out and buy a different aw4 (set up for 4wd)
i got it for $250 w/ a 30 day warranty at a local yard. ill keep you posted