AX4 swap to AX5

[hooddude]

Hello, I am new to this board. I am looking at buying a clean 2.5L AX4 2wd truck and switch it to a 4wd using a AX5 trans/ 207 transfer case and Dana 30 from an 86 2.8 V6 truck I am parting out. Will the AX5 bolt to the 2.5 and what will I need for clutch? I know it will not be very powerful, I am just looking for a small truck to get me back and forth to work in the winter. Any help will be greatly appreciated.

 

Thanks

Terry

[Eagle]

The AX4 and the AX5 are exactly the same, except that the rear section on the AX5 has a fifth gear unit and on the AX4 the rear section is empty. You should be able to remove the AX4 and bolt the AX5 right up in its place. But ...

 

The '86 will have an external slave cylinder. Depending on what year MJ you buy, the truck may have an internal slave. You can get around that by either: (a) Using the '86 as-is and converting to the external slave; or (B) swapping the tranny to the other bellhousing and keeping the truck with the original setup.

[hooddude]

The 2.5 truck is an 88. So is the bellhousing the same from a 2.5 to 2.8? One again thanks for your help!

 

Terry

[Geonovast]

Yes the 2.5 and 2.8 use the same bellhousing, however the 86 and 88 do not. The external bellhousing is different from the internal.

 

I highly, highly recommend using the 86 bellhousing and external slave setup. Internal slaves are horrendous. You'll just need to keep everything inside the 86 bellhousing, and you'll need to steal the clutch line from the 86. Everything is bolt on.

 

You may want to use the 86's pressure plate, the external and internal ones may be different, but I'm not 100% on that.

 

On my 91 2.5, I have a 93 AX-5, with an 86 bellhousing and external clutch setup.

[JeepcoMJ]

Yes the 2.5 and 2.8 use the same bellhousing, however the 86 and 88 do not. The external bellhousing is different from the internal.

 

I highly, highly recommend using the 86 bellhousing and external slave setup. Internal slaves are horrendous. You'll just need to keep everything inside the 86 bellhousing, and you'll need to steal the clutch line from the 86. Everything is bolt on.

 

You may want to use the 86's pressure plate, the external and internal ones may be different, but I'm not 100% on that.

 

On my 91 2.5, I have a 93 AX-5, with an 86 bellhousing and external clutch setup.

 

 

this is *mostly* true.

 

the bellhousings off of the ax5/ax4 are the same from 1984-sometime in the 90's.

 

the only difference is that the internal bellhousing doesn't have the pivot ball for the external slave throwout plate, and it doesn't have the studs or spacer to mount the external slave cylinder.

 

it is, however, machined and ready to go to be converted.

 

that said, I agree to just use the external bellhousing.

[pug]

I just did this conversion and i did not have any problems. So when i hooked all the wires up the ax5 did not have one of the sensors on it like the ax4. Going from 1990 1998. Sorry idont have picture but is on the passenger side with to small studs sticking out

[Eagle]

I just did this conversion and i did not have any problems. So when i hooked all the wires up the ax5 did not have one of the sensors on it like the ax4. Going from 1990 1998. Sorry idont have picture but is on the passenger side with to small studs sticking out

The AX5 is a manual transmission and it does not have any sensors. Might you be looking at the switch for the backup lights?

[pug]

There is the speedometer cable crankposition sensor the back up light plug and right above that there is another plug that was pluged in on the90 ax4. It is not onthe 98 ax5.

[Eagle]

The crankshaft position sensor is in the bellhousing, not the transmission, and it's on the driver's side not the passenger side.. And it has wires hanging off it, it isn't a "connector." And the speedometer is a mechanical cable, so it's not a connector, either. And it's also on the driver's side.

 

I have no idea what the other thing might be.

[Digitydan]

I know I’m reviving a dinosaur but did anyone do this? I found an AX5 off a 2.5l, 98, XJ that I want to slap in my 86 MJ. 

[Jeep Driver]

10 minutes ago, Digitydan said:

I know I’m reviving a dinosaur but did anyone do this? I found an AX5 off a 2.5l, 98, XJ that I want to slap in my 86 MJ. 

Make sure  you get the bell too. 

 

And, grab the axles if available.