Green Mesa XJ

PS I'm pretty sure you can only bolt it on one way, so unless it's damaged or you used the wrong year flywheel that should be ok. Sent from my iPhone using Tapatalk Pro

Not sure what the flywheel looks like I assume it's got a reluctor type deal spaced around it for the timing the engine via CPS. Did you use the 89 flywheel? Bad CPS is my first thought but it seem like something in the timing . flywheel could be damaged ? Sent from my iPhone using Tapatalk Pro

Ok, gotcha. The HO gauge shouldn't move either. Depending what year I had issues with the early clusters 84-87? Peeling printed circuit boards, went through a few before grabbing a 89-90 cluster. My 85s problem was the plug from the in tank sender to body harness, fabricated a fix and experimented with the senders to test the gauge and how it's wired. My guess is either the sender or the wiring/plug. I have spare 91 HO sending units I plugged it to the harness to test the gauge on the 85, which is weirdly backwards full reads empty and vise versa. Anyway if he was a spare sender around I start with something like that to test if the gauge is getting the signal and if so how accurately. If that checks out then it's got to be in the tank side of it. Sent from my iPhone using Tapatalk Pro

Same with the early XJ. Had a wiring problem, ended up making my own wiring from the sender to the body harness. Long process of hunting down the fault. Including finding a 86 XJ sender which was rare cause the first xj and mj were carbureted and didn't have a electric pump. Some times the plugs don't make good contact, sometime a bad wire or sender. Possibly gauge but I never had one of those go bad. The Sender can be tested in the tank with a meter. Little confused by 5 o'clock position. Sent from my iPhone using Tapatalk Pro

I think they'll fit with a little trimming. How'd you get so lucky to find a Dana 44? Sent from my iPhone using Tapatalk Pro

I'm not sure what the aw4 2wd sender and gear look like. I've got a picture of what the 92 np231 transfer case looks like to give you an idea of what you'll need to set it up on yours 1992 np231 speedometer sender and gear. 1992 np231 indicator switch And here is what the gear looks like in general, different color indicate which ratio it is and which tires size it corresponds with. I don't recall which one this is, it was at hand is all. The setup on the 1989 transfer case should look like this With a vacuum switch for the indicator and to engage the CAD on a disconnect axel (which you should avoid when you add a front axel to yours.) If I've confused anything please feel free to correct the record. Sent from my iPhone using Tapatalk Pro

How do i check to see what gear ratio my t-case has? the transfer case is set from the factory, ratio is on the tag. To get the speedometer accurate you chose the gear that best corresponds to your tire size. Hang on I'll be home in a bit. I'll get a picture of what the speedo gears look on The transfer case. Sent from my iPhone using Tapatalk Pro

If it has rear disc brakes those are a good swap. Sent from my iPhone using Tapatalk Pro

You don't want to try to convert the transmission to 4wd, it's more involved than just swapping the casing around. I think the 89 aw4 and 231 are the 21 spline and in 1991 they became 23 spline. There might be some harness differences for the plugs on the 89, but a aw4 is very similar all the years they used it with minor changes like plugs and spline count where the transfer case attaches. Far as the speedometer goes I believe you just need to get the speed sender for your year and the right gear for the transfer case. I don't think the the case changed much, I'm rebuilding a 1992 231 case to go in a 1985 XJ with a speedometer cable, I'm swapping. the speed gears from a 1988 np231 into the 1992 np231 case. I'm also putting in a ax15, but it's all still a work in progress. Might be able to swap the sender and gear off the transmission if the parts are the same, I'm guessing the gear will probably not be interchangeable, don't know about the sender though the plug should be the same 2wd or 4wd. I'm sure somebody who's done the swap will give you all the details you need to look out for. Edit : slow posting somebody is already filling in the details. Sent from my iPhone using Tapatalk Pro

I believe It should be cable driven with long gear. Sent from my iPhone using Tapatalk Pro

From my notes the flywheel (manual transmission) has to be balanced or off a 88-93 s10 2.8, supposedly Camaro flywheels are too thick. I can't find anything about 3.1 flywheels in my notes. I know I save the part #s someplace but have t found that file yet. Sent from my iPhone using Tapatalk Pro

I've been reading up on the 3.4 swap for a long time, but haven't done it yet. Most seem to get their old flywheel neutrally balanced, I thought there was something that made the 88 up a pain to find. What is the setup? I'm assuming 5speed, well because that what I have and I do have the part numbers for the swap save on the computer at home. I can look it up this afternoon. Though You may get your answer from someone who's done the swap first . Sent from my iPhone using Tapatalk Pro

I'm kind of wondering about the temperature senders, I think the 95 has two one for the pcm and one for the gauge Sort of sounds like the guard sender is wrong or the parts house gave you a idiot light sender instead. If they are correct for your xj then it sounds like something it gunked all to hell. If the PO tried the head gasket in a bottle then the radiator and heater core can be sealed up and just about anything and everything in between. Sent from my iPhone using Tapatalk Pro

One problem I had with the early style instrument clusters 84-87(?) was the printed circuit would start peeling and go bad, had four bad clusters. I tried to find a new printed circuit from jeep many year ago and it was no longer available, ended up finding a slightly newer cluster to use. May just be the southern heat that helped cause it. Sent from my iPhone using Tapatalk Pro

You can try car-part.com & Hollanderparts.com for the bellhousing. had no luck with that rout, every time a bellhousing come around it was gone before I could call. Scalped on eBay I bet. Finally got one off eBay for a reasonable price, it was mislisted but with the part # in the picture. Sent from my iPhone using Tapatalk Pro

Should be a metal tag on the rear cover. Normally see the tag bolted on the axel cover. If it's missing you can count the teeth on the gears, I'm not sure about the exact process . I'd just try to match the new front axel to the existing rears ratio. Sent from my iPhone using Tapatalk Pro

The 87 I likely to have that crappy Peugeot transmission ax15 didn't come along until 89-90 I think. On the renix just swap the ecu for a 89-90 for improved performance. The separation between a good driving renix and ho 4.0 is very thin. If this MJ 4.0 is on its way out get it cheap and swap all the 91 ho over with wiring. Better transmission for sure. Sent from my iPhone using Tapatalk Pro

I think 86 was the only MJ year with the 2.8 v6 which most agree is a underwhelming motor. Do you still have the 91 for a parts source? A lot of people seem interested in converting 2wd to 4wd, it's do able and there are plenty of parts around for it but if your in the market it might be better to hunt around for what you want to start with rather than try to built it up, unless it's the kind of project you are looking for. For a 2.8 v6 or 4cyl 4wd conversion you'll need a ax5 and np231 then a front Axel with a ratio to match the rear plus a ton of little things nobody thinks about until you are almost finished. Easiest to do if you've got the 91 or another 4wd donor. Sent from my iPhone using Tapatalk Pro

If you're doing that you'd need to re-gear the axel. And/or upgrade the engine and transmission at the same time as the 4wd conversion. If you just want to add 4wd that's different. As everybody said the ax5 is the ax4 gear to gear except for 5th. I thought maybe you were trying to keep it original by keeping the 4speed, no benefit to keeping it really. Depending on what your goals are for the MJ you might want to go more drastic than just adding 4wd. You've got a lot of work to do just to get 4wd, if you want the big tires you would need to regear or swap better ratio axels in since you've got to source the front axel anyway. if your going that far you could swap the engine and go for a lot more power. The simpler project is just adding 4wd, engine swaps get a lot more complicated depending on which direction you go. Sent from my iPhone using Tapatalk Pro

There are adapter kits for the ax15 to 4cyl. The Dakota bellhousing probably works the best but can be hard to find , on eBay they'll go for $200. The trick even with the right parts is lining up the shifter to the body correctly. I think many solve this problem with a aftermarket shifter. In this case just about any 4wd AX4 or AX5 from 1984-early 90s should work. Sent from my iPhone using Tapatalk Pro

If you've got a 2.5 4cyl then the 4wd ax-4 will keep you manual 4 speed. Grab a 4cyl np231 transfer case to go with it. The 4cy have less heavy duty parts and fewer spline count on the transfer case to transmission. For a while the early MJ & Xj 6cyl & 4cyl shared the same transfer case, at some point the 6cyl got a tougher transfer case. I couldn't tell you which year to look for off the top of my head. Although it might be easier to find a ax5 (5 speed) transfer case combo. Bascily any Cherokee or Comanche 4cyl 4x4 manual transmission will work. It has to be XJ or mj because the tail case is clocked for the transfer case to fit the body. The transfer cases themselves can fit a variety of jeeps. I don't disagree the ax15 is the better transmission however the there is a lot to converting a 4.0 6cyl transmission to fit the 4cyl. Also the 4cyl transmission seem to work better with the power bands of the 4cyl. I know folks have cause to not like the ax-4 & ax-5 but they usually are tough enough for the 4cyl. the parts search shows the 4 speed 4x4 (ax-4) interchanges 1984-1990 Any 4x4 4cy transmission should be a direct fit from 1984(?) they show 1987-1993 on the computer for the 5 speed , it actually should work beyond but I'm not sure of the small changes. Just find a combo of ax-5 or ax-4 and np231, or maybe np242 if that was an option. You can do a search for used transmission with car-part.com & Hollanderparts.com You going to need a lot of parts to convert 2wd to 4wd, probably want to avoid to vacuum disconnect front axel too (aka CAD axel) Sent from my iPhone using Tapatalk Pro

For what it is worth I looked up who we got the radiator from, it was Vista-pro 436020 "with max cooling" ( guess that's their term for towing package) all metal Cost $187 in 2010 dollars . Rock Auto doesn't even list them any more. Summit used to stock it but list a new part # sum-382012, that supposedly interchanges with the vista-pro #. looks all metal. Cost $270. Edit: fits 91-01 XJ & 91-92 MJ Sent from my iPhone using Tapatalk Pro

There used to be a few reliable names for radiators, heater cores and evaporators. Those companies have other merged, been bought out or started outsourcing to china. Hard to know who's the good name in the market place because so many are reboxed/renamed across the stores and online. I paid at bit more for the 92 cherokee radiator 6-8 years ago when the OE radiator finally gave up the ghost. I forget who we got it from but it doesn't matter because they could have folded or outsource now. Just thought I would mention another for overheating cause is a clogged catalytic converter can cause overheating, but it's probably the radiator in this instance. I knew of someone who almost killed a new motor because the cats were clogged. It started overheating on the highway, seemed ok in town. Thinking back on it I'm not sure they would have know the difference if it wasn't ok in town... Anyway it just a thought as to cause. Sent from my iPhone using Tapatalk Pro

Ratcheting breaker bar!? What sorcery is this? (Googles) Oh! now I got to get one! BTW on the OTC kit if you use the otc clamp make sure you have the exact size socket, it's under so much tension even a little off will spin freely. I think it was 13/16 or 21mm, 3 year old ran off with the socket when I wasn't looking. Tried the the next size then when to the hardware store for the correct one. No idea where the boy dropped it. Could be anywhere from toy box to flower bed. Sent from my iPhone using Tapatalk Pro

I've got two np231 cases (91 & 92) , both have the port in the front like you're new one (as do the 88 np231 & 85 np207 I have) . thought the back port for the switch was later years. I think you can just swap the vacuum switch to that position you ought to have enough vacuum harness since it was connecting to the back of the case. If you don't have a vacuum disconnect axel you could eliminate the vacuum part of it if you want. Sent from my iPhone using Tapatalk Pro