Trans and Transfer Case 4x4 Swap Questions

[Rymanrph]

I'm in the process of converting my 2wd to 4wd and I have some parts questions.

 

I have a '95 AX15 from a Cherokee with the external slave. The slave line was cut at the JY. Can the slave from the new tranny be used with the existing slave line in my vehicle now or will I need to buy a new slave and line? I've not dealt with these parts before, so I'm a little confused.

 

Will I need to replace my speedometer cable? I was under the impression that the newer vehicles use an electronic set-up. Also, I assume that the cable won't be long enough now that it has to connect to the transfer case and not the transmission. If so what cable should I get and will I have any problems connecting it to my gauge cluster?

 

I got the '95 transmission to get the external slave, but I'm just not sure what compatibility problems I'll have with my 1990 truck. I know these are probably noob questions, but I've never done a transmission swap before so I'd rather get the questions answered now before I've pulled everything out of the truck and I can't drive it anymore.

 

Thanks.

[Geonovast]

You shouldn't have any problems using the external slave. If you got everything from the 95, it should go in just fine. I converted my 91 2.5 to an external slave AX-5 from an 86, and I used a clutch master and line from an 88 BA 10/5. I picked up some brake line, and made my own section running from the rubber part to the slave. (older external AX-5s had the slave on the passenger side, I believe all external AX-15s are on the driver's)

 

For some reason I'm thinking that the Renix and HO AX-15s have a different diameter input shaft tip for the pilot bushing. Wouldn't hurt to measure those first to make sure you don't need a new pilot bushing.

 

You'll probably need a new speedometer cable. Good news is, however, that the entire sending unit out of your 2wd trans will go into the 231 just fine. You don't need to worry about the electronics, pop the electric sender out, put your cable one in, and sell off the electric one.

 

Just go get a 4.0 4wd 5 speed cable either from a JY, brand new, or someone on here may have one. A cable from mid 87 - 90 should work perfectly.

 

Just take your time and don't rush anything. The best part about an external slave, is you can detach the bellhousing from the transmission, and using a clutch alignment tool, you can bolt the bellhousing with all the clutch stuff up to the motor with the trans out of the truck, and test it to make sure everything's working. If you need more details on the test, I can give you step by step instructions.

[Rymanrph]

The best part about an external slave, is you can detach the bellhousing from the transmission, and using a clutch alignment tool, you can bolt the bellhousing with all the clutch stuff up to the motor with the trans out of the truck, and test it to make sure everything's working. If you need more details on the test, I can give you step by step instructions.

 

That would be awesome. Thanks!

[Pete M]

how short was the slave line cut? I've successfully adapted 2 Renix era MJs to external slaves using a simple 1/4 to 5/16" compression fitting from the hardware store. You can't use that type of fitting on brake lines, but clutch lines are under much lower pressures.

 

 

 

 

 

 

Also, the guts that go in the t-case for the speedo are indeed swappable. you may need to mix and match with the little gears or stub shafts to make it work.

 

[Rymanrph]

 

That's the only shot I have of the transmission right now. If you look hard enough, you'll see that the line was cut right at the slave (maybe a half inch at most sticks out).

 

Does the comanche use a short or long style speedo gear shaft? I have several long shafts left over from working on the TJ that I can look at.

[Pete M]

my 90 only had a half inch or so of the original external slave line left and I found a way to make it work. You could always try to get your hands on a used slave with more line left on it.

[Rymanrph]

my 90 only had a half inch or so of the original external slave line left and I found a way to make it work. You could always try to get your hands on a used slave with more line left on it.

 

That's good to know. I'll check the pull a part next time I go. Unfortunately, stick shift cherokees are hard to come by at my yard. The last time I went 1 out of 8 or 9 cherokees was a manual and it was a Peugot unit (I was looking for transfer case linkage).

[Pete M]

yeah, most XJs were autos. keep an eye on TJ/YJs. they are more likely to be sticks.

[comanche09]

I'll be going down this road soon too! :cheers: here's some info I've gathered up preparing my swap:

 

You can order the complete OEM 94?-96 XJ master cylinder and slave assembly complete with lines pre-bled from mopardiscountparts.com for around $140 shipped (P/N 52104110)

 

You can reuse your clutch (P/N 4713323) and flywheel (P/N 33002672), but might consider replacing same if you have the cash. The clutch release bearing (P/N 53008342) comes with some parts store clutch kits. Good idea to replace that too.

 

Try the pilot bushing from a 73-75 CJ5 with a 304 V8, 3spd manual. $4

 

You'll have to cut/splice reverse light wiring at trans in if you want em.

 

Not sure if your t-case came from the '95, but make sure it has the 23 spline input shaft, pre-H.O. (excluding AX-15 equipped) are 21 spline.

 

Hope that helps! :cheers:

[Rymanrph]

I'll be going down this road soon too! :cheers: here's some info I've gathered up preparing my swap:

 

You can order the complete OEM 94?-96 XJ master cylinder and slave assembly complete with lines pre-bled from mopardiscountparts.com for around $140 shipped (P/N 52104110)

 

You can reuse your clutch (P/N 4713323) and flywheel (P/N 33002672), but might consider replacing same if you have the cash. The clutch release bearing (P/N 53008342) comes with some parts store clutch kits. Good idea to replace that too.

 

Try the pilot bushing from a 73-75 CJ5 with a 304 V8, 3spd manual. $4

 

You'll have to cut/splice reverse light wiring at trans in if you want em.

 

Not sure if your t-case came from the '95, but make sure it has the 23 spline input shaft, pre-H.O. (excluding AX-15 equipped) are 21 spline.

 

Hope that helps! :cheers:

 

That assembly might be a good idea. Sounds like it might be a little much, but I might go that way for easy of installation. The clutch was supposedly replaced before I bought the vehicle, so hopefully its good (I'll still inspect it). The transfer case should work; I specifically asked for the same spline count and he assured me that they would work. If not, they're a big outfit and can get me whatever I need.

 

All that helped, so thank you.

[Geonovast]

You have a PM with the test.

[Rymanrph]

Bringing up an old topic of mine. I was thinking of starting my transmission swap this weekend, but I read that the slave cylinders were sealed units and can't be bled. So, since I don't have the complete master/slave assembly from my '95 AX-15, can I not use it? The only adjustment I can see is an allen head bolt. Would I be better off just buying the new assembly listed above?

[Geonovast]

Bringing up an old topic of mine. I was thinking of starting my transmission swap this weekend, but I read that the slave cylinders were sealed units and can't be bled. So, since I don't have the complete master/slave assembly from my '95 AX-15, can I not use it? The only adjustment I can see is an allen head bolt. Would I be better off just buying the new assembly listed above?

 

Wherever you read that, they are incorrect. Both internal and external slaves are bleedable.

[Rymanrph]

That's weird cause everything I've read on naxja.org says that they are sealed and non serviceable. A couple people even referenced the factory service manual. Here's a link to one of the threads:

 

http://naxja.org/forum/showthread.php?t=79776

 

Is the allen head bolt the bleeder? Cause I didn't see anything else that looked like a bleeder nipple.

[Geonovast]

That's weird cause everything I've read on naxja.org says that they are sealed and non serviceable. A couple people even referenced the factory service manual. Here's a link to one of the threads:

 

http://naxja.org/forum/showthread.php?t=79776

 

Is the allen head bolt the bleeder? Cause I didn't see anything else that looked like a bleeder nipple.

 

Serviceable and bleedable are two completely different things. Serviceable means you could easily repair inner parts and/or rebuild the unit. It is impossible to install any part of a hydraulic system without bleeding it.

 

There's a bleeder screw on the slave. It'll have the hex part, and a nipple with a hole in the end that you can quick pop a hose onto to direct the flow of fluid.

 

What they're referring to... is you can buy the whole setup, bench bled. Just means you don't have to do the bleeding, but the system is bleedable.

[Pete M]

people swore left and right that my 99 TJ slave was not bleed-able. :dunno: I almost believed them, until i found that little allen screw on the bottom. bled the line just fine. :thumbsup: No clue as to where that rumor comes from. :hmm:

[comanche09]

I just got that Mopar Master/Slave assembly in the mail. The box had a nice big wet spot on it... I love CC, glad to know its bleedable. :cheers:

 

Pete, You wouldn't have a speedo gear for 3.55 gears and 31" tires laying around would ya?

[Rymanrph]

I just got that Mopar Master/Slave assembly in the mail. The box had a nice big wet spot on it... I love CC, glad to know its bleedable. :cheers:

 

Pete, You wouldn't have a speedo gear for 3.55 gears and 31" tires laying around would ya?

 

Man did I ever get lucky with my speedo gear. I knew my speedometer was off when I was on my 2wd 3.07 gears with 29" tires. When I swapped in the 3.55s and the 31s, my speedometer is dead on. Does the gear in the transmission for 2wd work in the transfer case for 4wd?

[Pete M]

I just got that Mopar Master/Slave assembly in the mail. The box had a nice big wet spot on it... I love CC, glad to know its bleedable. :cheers:

 

Pete, You wouldn't have a speedo gear for 3.55 gears and 31" tires laying around would ya?

 

 

nah. not even my 90 (31s/3.55s) has the exact correct gear. :(