Wesleypipesyo Posted October 10, 2014 Share Posted October 10, 2014 It would seem that I am going to have to be a touch less picky in trying to find a truck to buy. So I will throw it this out there and see what sticks. Which is easier/less involved? Manual to auto swap or 2wd to 4wd swap. The manual to auto swap seems to be a lot of wiring. You need to replace the bulk of the wiring harness. You need a new cross member. A new transmission with bellhousing and other hard ware. I have seen some people say that you need a new steering column. What do you need for the 4x4 swap beside the tcase, front axle, drive shafts, and center console? Thanks. Jeff Link to comment Share on other sites More sharing options...
Blue88Comanche Posted October 10, 2014 Share Posted October 10, 2014 if its a manual 2wd to manual 4wd, 4wd version of the transmission transfer case and all the linkages for the 4wd shifter front axle front drive shaft shorten or replace the rear drive shaft. thats all i can think of at he moment Link to comment Share on other sites More sharing options...
Wesleypipesyo Posted October 10, 2014 Author Share Posted October 10, 2014 The goal is to end up with an auto 4x4. I am going to look at a beat up 4x4 next weekend. But it is a 2.5l 5spd. I much prefer auto for offroading. And the truck will end up sitting in DC rush hour traffic atleast once a week. Link to comment Share on other sites More sharing options...
Blue88Comanche Posted October 10, 2014 Share Posted October 10, 2014 there is a thread in the DIY to convert from a BA-10/5, AX-15, or AW-4 to an AX-15, or AW4 I have no experience with 2.5Ls all I know is they came with AX-4 and AX-5 manual transmissions with 3.73 to 4.56 gearing. I have no idea what auto trans they use. Link to comment Share on other sites More sharing options...
joester1908 Posted October 10, 2014 Share Posted October 10, 2014 I did a manual swap on my 90. Wiring wise, all you have to do is ground the NSS wiring. You can use the automatic computer with the manual. There is a transmission computer that plugs in, and is located on the lower dash panel on the passenger side. It can be pulled out completely. Then, you will have a white and a black plug on the firewall where the NSS and the transmission harness plug in to the main harness. You need to bridge 2 of the pins on the NSS harness. A simple butt connector will do. You won't have reverse lights if you go this route. They could be wired in easily. In fact, I believe the manuals have a harness that plugs in there that you can just plug and play, but don't quote me on that. The only cutting you have to do is the 3 holes for the slave cyl master. There are 3 dimples next to the brake booster. The top 2 holes line up with the bracket, then you have to get a hole saw and drill out a larger size hole. Also, the T case linkage is a little crooked if you don't drill a new hole for the linkage. It can be easily done. You need: transmission transfer case (if you have a 21 spline aw4, AX15 is 23) cross member (optional) steering column (optional, the manual steering column has the push button lock) drivelines (front and rear) Shift boots (one screws to the floor and one goes in the column) cover for the floor hump (The one for the manual is just a hole with a shift boot over it) brake and clutch pedal clutch flywheel slave cylinder and master w/bracket. throwout bearing A manual swap is a big job, but all plug and play. Link to comment Share on other sites More sharing options...
dunnc1991 Posted October 10, 2014 Share Posted October 10, 2014 I did a manual swap on my 90. Wiring wise, all you have to do is ground the NSS wiring. You can use the automatic computer with the manual. There is a transmission computer that plugs in, and is located on the lower dash panel on the passenger side. It can be pulled out completely. Then, you will have a white and a black plug on the firewall where the NSS and the transmission harness plug in to the main harness. You need to bridge 2 of the pins on the NSS harness. A simple butt connector will do. You won't have reverse lights if you go this route. They could be wired in easily. In fact, I believe the manuals have a harness that plugs in there that you can just plug and play, but don't quote me on that. The only cutting you have to do is the 3 holes for the slave cyl master. There are 3 dimples next to the brake booster. The top 2 holes line up with the bracket, then you have to get a hole saw and drill out a larger size hole. Also, the T case linkage is a little crooked if you don't drill a new hole for the linkage. It can be easily done. You need: transmission transfer case (if you have a 21 spline aw4, AX15 is 23) cross member (optional) steering column (optional, the manual steering column has the push button lock) drivelines (front and rear) Shift boots (one screws to the floor and one goes in the column) cover for the floor hump (The one for the manual is just a hole with a shift boot over it) brake and clutch pedal clutch flywheel slave cylinder and master w/bracket. throwout bearing A manual swap is a big job, but all plug and play. He's asking about a manual to auto swap.. Link to comment Share on other sites More sharing options...
Wesleypipesyo Posted October 10, 2014 Author Share Posted October 10, 2014 I have seen a little on auto to manual. But I want to end up with an auto. That and 4x4. Link to comment Share on other sites More sharing options...
relyt120 Posted October 10, 2014 Share Posted October 10, 2014 no matter what if you are starting with something not auto 4x4 you will need a transfer case and transmission from auto 4x4...so the real question is front axle swap or tb and wiring swap. I say go for an auto and swap in 4x4 to avoid having to mess with wiring . You can get the axle ready to go outside the vehicle and still drive it but the wiring and stuff takes you out if commission till its finished. Link to comment Share on other sites More sharing options...
BryceOJ Posted October 11, 2014 Share Posted October 11, 2014 there is a thread in the DIY to convert from a BA-10/5, AX-15, or AW-4 to an AX-15, or AW4 I have no experience with 2.5Ls all I know is they came with AX-4 and AX-5 manual transmissions with 3.73 to 4.56 gearing. I have no idea what auto trans they use. 2.5Ls came with AW4 auto trans 87 and after I believe (?). But, as Ive done lots of researching for mine I find that 2.5ls autos don't seem very common. Mine is column shift, 2wd. and the rear is 4.56. I'm gonna hijack this thread for a moment. I too have questions about swapping for 4wd. would it be too much work to put 4wd on mine and be more worth it to just find another comanche with even the 4.0l and 4wd? Not sure if a 2.5l auto 2wd swap to 2.5l auto 4wd will take a lot of work? would a 4.0L AW4 4wd trans work? or is there minor differences in the AW4 for a 4.0 and 2.5? Link to comment Share on other sites More sharing options...
Wesleypipesyo Posted October 11, 2014 Author Share Posted October 11, 2014 I am hoping the deal of a life time drops into my lap when I get back from Alabama. Link to comment Share on other sites More sharing options...
Eagle Posted October 11, 2014 Share Posted October 11, 2014 What do you need for the 4x4 swap beside the tcase, front axle, drive shafts, and center console? You need a transmission to make the 2WD to 4WD swap, too, unless you think it's easier to tear apart your transmission and change the output shaft and tail cone for a transfer case input shaft and rear tranny housing set up to mate with the transfer case. The AW4 has a separate TCU, so going from manual to automatic doesn't require RE-wiring anything in the truck. Just add the TCU wiring harness. Link to comment Share on other sites More sharing options...
Incommando Posted October 12, 2014 Share Posted October 12, 2014 Buying a 2wd auto and converting it to a 4wd auto is cake. Link to comment Share on other sites More sharing options...
Wesleypipesyo Posted October 12, 2014 Author Share Posted October 12, 2014 Do you have any pictures of the tunnel where you put the shifter? Or any of the tcase mounted? Thanks Link to comment Share on other sites More sharing options...
joester1908 Posted October 13, 2014 Share Posted October 13, 2014 my bad, hahah. I guess you're just doing the opposite. You have to swap the computer, and gonna have a hole in the firewall. Link to comment Share on other sites More sharing options...
joester1908 Posted October 13, 2014 Share Posted October 13, 2014 point being, it seems to me a 4x4 swap would be much easier. I have a column shift steering column you can have if you pay shipping, but it requires some assembly. Personally, id go for the 4wd swap. 4wd AW4s are everywhere, cheap too :thumbsup: Link to comment Share on other sites More sharing options...
G.I. Jomanche Posted December 22, 2014 Share Posted December 22, 2014 I'm trying to follow you guys on this with my own donor swap, just a little lost. I have an 86 2.5 custom 4x4 and my donor is a 91 4.0L auto 2wd. If I'm understanding this right the t-case splines are different and I may need to swap the yoke on the driveshaft as well right? output shaft from the trans isn't the same spline from ax4 and the length differs from 4x4 to 2x4? In any case I will freeball the front differential until a t-case is available. I have ecu, clusters and a motor swap in front of me now, cart before the horse right. Plan on swapping everything back into the donor and give it to my 17yr old brother. So leave the t-case for him to find a front end in the future assuming he don't wreck it another club member guys! Any good tech advice on my swap? Link to comment Share on other sites More sharing options...
Jeep Driver Posted December 22, 2014 Share Posted December 22, 2014 I'm trying to follow you guys on this with my own donor swap, just a little lost. I have an 86 2.5 custom 4x4 and my donor is a 91 4.0L auto 2wd. If I'm understanding this right the t-case splines are different and I may need to swap the yoke on the driveshaft as well right? output shaft from the trans isn't the same spline from ax4 and the length differs from 4x4 to 2x4? In any case I will freeball the front differential until a t-case is available. I have ecu, clusters and a motor swap in front of me now, cart before the horse right. Plan on swapping everything back into the donor and give it to my 17yr old brother. So leave the t-case for him to find a front end in the future assuming he don't wreck it another club member guys! Any good tech advice on my swap? You cannot use a 2wd trans in a 4wd truck. Link to comment Share on other sites More sharing options...
Dadinator Posted December 22, 2014 Share Posted December 22, 2014 If doing a 4x4 swap, make sure your new front axle is the same gear ratio as the rear. Link to comment Share on other sites More sharing options...
richasco Posted December 22, 2014 Share Posted December 22, 2014 Start with a truck that has the engine and transmission that you want. The 4wd swap is much easier/cheaper/less time consuming. As far as the transmission tunnel, when you lift up the carpet you will see a blanking plate with four screws, remove it and put the transfer case shifter in it's place. And 4wd AW4s are plentiful and cheap, I got two from CL for free and haven't been able to give them away. Link to comment Share on other sites More sharing options...
Wesleypipesyo Posted December 24, 2014 Author Share Posted December 24, 2014 I gave up on this idea. I am still looking for a truck with the right drive train. I hope to go look at a truck Friday. It is a little over 4 hours away. I will be unhappy if the people are lying about the condition of the truck. But it is pretty close to what I want. Link to comment Share on other sites More sharing options...
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