1987Comanche Posted March 23, 2014 Share Posted March 23, 2014 So I scored a 168K mile external slave 4X4 AX-15 at the jy yesterday and am debating whether I should convert Georgia to 4WD. P/N on the trans is 52108047 and it came from a '94. The 231J transfer case was shot (broken chain, hole in case) so I left it. Front D/S was also gone. I've done some additional research and I'm trying to determine the correct donor(s) for a 231J. From what I can see it looks like a 6 cyl '94-95 XJ is the only 231 donor, regardless of whether it's an AX-15 or AW4. 412-309, CHEROKEE 94-95 NP231, 6 cyl, Ident: 52098487, New Process 231. The trans itself shows the following interchange: 400-2701, CHEROKEE 94-99 M.T.; 4x4, 6 cyl, 5 speed M.T., AX15 Front Driveshaft looks pretty wide open: 430-2721, basically 87-01 XJ/MJ with a 6 cyl and M/T Rear Driveshaft is 87-92 SWB M/T 6 cyl MJ: 431-2737, COMANCHE 87 113" WB, 4x4, MT, 6 cyl, COMANCHE 88-92 113" WB, 4x4, MT, 6 cyl, w/o Spicer 44 axle Front axle is 3.07 M/T non-ABS. 434-1562c, CHEROKEE 90-93 w/o vacuum disconnect; w/o ABS; 3.07 ratio CHEROKEE 94-99 w/o ABS; LHD, 3.07 ratio So here are my questions: -If the trans interchanges from 94-99, why wouldn't the 231 interchange from 94-99? -I'm assuming the difference between the early AX-15 and the later AX-15 is the input shaft dia and external/internal. Would the 90-93 231 fit? -If the transfer case is a direct interchange between manual and auto, why isn't the front driveshaft interchangeable as well? Really I'm down to 2 possibiliites: -Swap the bellhousing and front bearing retainer from my internal 2WD AX-15 and sell the 4X4 AX-15. -Collect parts for a 4X4 conversion. Link to comment Share on other sites More sharing options...
Alexia Posted March 24, 2014 Share Posted March 24, 2014 Any 1992 to 2006 NP231/NV231 from a XJ, ZJ, or TJ with the correct length input gear will work. Novak shows that the AX15 needs a short input gear on the transfer case. That is what makes an easy swap for a 231 annoying because medium input gears are much more common and heavily used on the automatic transmissions. So if you can not find a transfer case that is an easy direct swap there is always the option of breaking the case open and swapping input gears. Link to comment Share on other sites More sharing options...
64 Cheyenne Posted March 24, 2014 Share Posted March 24, 2014 "there is always the option of breaking the case open and swapping input gears." Thats what I did, bought the correct input from a CC member, split the cases, replaced the gear. Honestly, not a hard job at all, just need duck bill snap ring pliers, Powerblock had an episode where they split a 231 case... Link to comment Share on other sites More sharing options...
Mattwheels Posted March 24, 2014 Share Posted March 24, 2014 Even though it says to use a short input, I've heard that you can use a medium without a problem as theres quite a bit of room left even on the short input. Link to comment Share on other sites More sharing options...
1987Comanche Posted March 25, 2014 Author Share Posted March 25, 2014 I'd be ok with swapping in the short input gear if needed and I could find one. I recently rebuilt the NVG246 in my Suburban and it's more complicated than the 231 appears to be. Has anyone tried using a medium length input shaft 231 with the AX-15? In every JY I've been to the AW4 outnumbers the AX-15 by 10 to 1. I did some additional research and found some MOPAR Transfer case #s. None of these are separated by M/T vs A/T. According to the interchange these would swap freely. 91-93: 52097522 94-95: 52098487 97+: 52099212 Has anyone hooked one of these 3 P/Ns to an AX-15? I'm going to see if I can find something that references input shaft length to these numbers. Alexia: I see your point. What should be a simple interchange is insanely complex. Link to comment Share on other sites More sharing options...
Alexia Posted March 25, 2014 Share Posted March 25, 2014 MOPAR 52099212 - 1997 Parts catalog says it was used behind the AW4 and AX15 with the 4.0L engine. So assuming there is not some internal difference with earlier AX15 transmissions then it could worth a shot mating a medium input transfer case. Link to comment Share on other sites More sharing options...
Blue88Comanche Posted March 25, 2014 Share Posted March 25, 2014 I'd be ok with swapping in the short input gear if needed and I could find one. I recently rebuilt the NVG246 in my Suburban and it's more complicated than the 231 appears to be. Has anyone tried using a medium length input shaft 231 with the AX-15? In every JY I've been to the AW4 outnumbers the AX-15 by 10 to 1. I did some additional research and found some MOPAR Transfer case #s. None of these are separated by M/T vs A/T. According to the interchange these would swap freely. 91-93: 52097522 94-95: 52098487 97+: 52099212 Has anyone hooked one of these 3 P/Ns to an AX-15? I'm going to see if I can find something that references input shaft length to these numbers. Alexia: I see your point. What should be a simple interchange is insanely complex. I have a NP242J on my AX-15 and if i recall correctly it is a med length input. so does it work, Yes... Do I have any issues, No... Link to comment Share on other sites More sharing options...
Rockfrog Posted March 25, 2014 Share Posted March 25, 2014 The only reason they split off at 96 is the 96+ tcases used an externally sealed output housing. Previos cases used an inernally sealed output housing. Its all swappable parts .. either swap output slip yokes or swap the whole rear output housing on the transfer case. As for the AX-15 .. they were always 23 spline have plenty of room inside the output adapter to take any XJ/YJ/MJ/TJ input gear ... the long input gears were found on V8 ZJs. The only concern about input gear swapping is the 1994 gear pitch change. So when swapping 231 and 242 parts about go pre 94 to pre 94 and post 94 to post 94. The gears are easily distinguished by a flatter tooth profile on the pre 94 gears. Link to comment Share on other sites More sharing options...
1987Comanche Posted March 25, 2014 Author Share Posted March 25, 2014 I found a pretty good writeup on the input shafts today: http://www.jeepforum.com/forum/f13/transfer-case-swap-info-np249-np231-np242-685644/ Based on this and input from everyone who replied it looks like any 231 from 91-95 is easiest swap. 96 is listed as a 1 yr only interchange but I'm not sure why...have to research that. 97+ looks like it will work as well, provided I grab the yoke off the rear driveshaft as well. Am I safe in assuming the floor lever and linkage are identical between M/T and A/T equipped XJ/MJ? I'll have to grab that with the Transfer case Link to comment Share on other sites More sharing options...
Rockfrog Posted March 26, 2014 Share Posted March 26, 2014 the transmission mounted portion of the linkage are specific to each trans ... inside the cab its all the same. Link to comment Share on other sites More sharing options...
Tactical Bacon Posted March 26, 2014 Share Posted March 26, 2014 You should save yourself the headache and just sell it to someone who knows they are going to 4x4 swap their Manche, not unlike myself. Link to comment Share on other sites More sharing options...
1987Comanche Posted March 27, 2014 Author Share Posted March 27, 2014 the transmission mounted portion of the linkage are specific to each trans ... inside the cab its all the same. So I have to look for another AX-15 MJ/XJ to scrounge at least the linkage & front driveshaft from. Bummer. Any chance the BA 10/5 Transfer case linkage would work? You should save yourself the headache and just sell it to someone who knows they are going to 4x4 swap their Manche, not unlike myself. I think I've found someone who knows they're going to do the 4X4 swap... me :). If, for some reason I decide against it I'll keep you in mind. OneOverZero has first right of refusal, however. I took a closer look at the output shaft area of the AX-15 tonight and I think that even the long input shaft 231 would fit with no issues: Wide open: The cavity is almost 3" deep from the seal lip to what I believe is the reverse gear cluster: Link to comment Share on other sites More sharing options...
Alexia Posted March 27, 2014 Share Posted March 27, 2014 the transmission mounted portion of the linkage are specific to each trans ... inside the cab its all the same. So I have to look for another AX-15 MJ/XJ to scrounge at least the linkage & front driveshaft from. Bummer. Any chance the BA 10/5 Transfer case linkage would work? There is enough adjustment in the linkages that it may work. I used the NP231 shifter linkage on my LJ with the NP242 I installed and made a very minor adjustment. You could always buy Novak's cable shifter and not have to worry about it. Link to comment Share on other sites More sharing options...
Blue88Comanche Posted March 27, 2014 Share Posted March 27, 2014 the transmission mounted portion of the linkage are specific to each trans ... inside the cab its all the same. So I have to look for another AX-15 MJ/XJ to scrounge at least the linkage & front driveshaft from. Bummer. Any chance the BA 10/5 Transfer case linkage would work? There is enough adjustment in the linkages that it may work. I used the NP231 shifter linkage on my LJ with the NP242 I installed and made a very minor adjustment. You could always buy Novak's cable shifter and not have to worry about it. The problem will be the transmission side TC shifter bracket. When I went from BA-10 to AX-15 I did not have that bracket and could not hook anything up. And those brackets are different. That's why I bought the Novak cable shifter kit. Link to comment Share on other sites More sharing options...
1987Comanche Posted March 27, 2014 Author Share Posted March 27, 2014 I dug through the archives and found a pic of Maura's shift linkage (231J with AX-15). Does anyone have a pic of the AW4 231J linkage for comparison? For reference Maura had a 53009209 231J transfer case: Link to comment Share on other sites More sharing options...
Blue88Comanche Posted March 28, 2014 Share Posted March 28, 2014 Look on my build thread for the Novak cable install. I had a reference article to another method of replacing the linkage. It would need a junkyard trip and a few items from the hardware store. I think it's page 9. But I know it's there. I can post a link here when I get back to a computer if you like. Edit: I also have the Novak install in the DIY section it will also have that reference. Link to comment Share on other sites More sharing options...
Rockfrog Posted March 28, 2014 Share Posted March 28, 2014 it's that bracket that bolts to the transmission that differs ... the rest is all the same. you could always just go direct link shift and save a few hundred headaches. Then 2wd would be all the way back and 4wd LO would be all the way forward, if you can live with that. Link to comment Share on other sites More sharing options...
Blue88Comanche Posted March 28, 2014 Share Posted March 28, 2014 Here is that alternative linkage i was referring to http://www.bsfab.net/?p=26 Link to comment Share on other sites More sharing options...
1987Comanche Posted March 29, 2014 Author Share Posted March 29, 2014 The alternative linkage doesn't look too bad though there definitely is some assembly required. I'll have to make the determination on what to pursue when I have more parts gathered. I think I'll need to find another 4WD AX-15 XJ in order to scavenge the front driveshaft and axle. I was hoping everything (linkage, bracket, etc) was identical between AX-15 and AW-4 but I guess I'm not that lucky... Link to comment Share on other sites More sharing options...
Blue88Comanche Posted March 29, 2014 Share Posted March 29, 2014 When you get the linkage be sure to get everything. Including the body side linkage mount. I think those where also different between the transmissions. Link to comment Share on other sites More sharing options...
1987Comanche Posted April 6, 2014 Author Share Posted April 6, 2014 I might have a line on a transfer case & front driveshaft out of an AX-15 equipped '96 XJ sport. From what I can tell the '96 NP231 most likely uses the external slip yoke at the rear output shaft (rubber boot), correct? So I would need the correct yoke to go with the transfer case. I found 2 measurements for a SWB AX-15/NP231 D35 MJ driveshaft: 43 1/8" and, from the CC thread, 43.25". Would this measurement change with the '96+ style slip yoke? It looks a bit longer than the earlier style that uses the yoke to retain fluid in the transfer case. Is the 1/8" discrepancy anything to worry about? Link to comment Share on other sites More sharing options...
Alexia Posted April 6, 2014 Share Posted April 6, 2014 Yes, 1996+ is external slip yoke. 1" of minimum slip travel is typical depending on lift height. My quick calculations show only 0.5" of slip is technically needed for a stock height Comanche. Link to comment Share on other sites More sharing options...
1987Comanche Posted April 6, 2014 Author Share Posted April 6, 2014 I read through the driveshaft measurement procedure but want to make sure I have it straight. After trans/t-case is installed I should install the yoke, bottom it out, then back off 1". Center to center distance from midpoint of U joints would give me the correct measurement, right? Link to comment Share on other sites More sharing options...
1987Comanche Posted April 7, 2014 Author Share Posted April 7, 2014 Spent some time with the Mopar parts manuals and Hollander interchange manual and it looks like most of the parts from my '92 2WD axle should fit the 96 4WD Axle. A$$uming the deal doesn't fall through I was looking to reuse the following: Track bar: 52007118 (same) UCA : 52038130 (same) LCA: 52001162 (same) Rotors: 52008464 for 92, 52008440 for 96. Hollander is 530-1713 for both so it looks like they interchange. Calipers: 52529845 (same) The spring interchange had a ton of different part numbers. I was going to reuse the current 2WD springs unless there's a reason not to. Do I need anything other than the bare axle with spindles from the donor? Link to comment Share on other sites More sharing options...
1987Comanche Posted April 8, 2014 Author Share Posted April 8, 2014 Looking at the crossmember and trans bracket interchange and, as far as I can tell, there doesn't appear to be any difference between the 2WD and 4WD X-member and bracket. Mopar parts manual lists the following: M/T X-member: 52003929 M/T bracket: 52003927 Am I correct in saying that I can reuse my current 2WD ax-15 X-member and bracket with the 4WD trans? It certainly looks like I can. Link to comment Share on other sites More sharing options...
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