2wd to 4wd swap help

[th3m4nm4rcu5]

hey guys, i need a little help.

 

i have

89 jeep comanche 5 speed 2wd. pigeot trans ba10/5

 

I'm planning on the 4wd conversion, my donar is an 89 jeep xj 4x4 5 speed with the pigeot ba10/5 trans i believe.

ive already pulled its trans, transfer case, clutch, flywheel, front axel (d30 with vaccume acuated axel disconnect) and driveshafts. i have already converted the d30s axel shafts with a 96 xjs, with the bigger u joints. ive replaced the u joints and put new axel seals in the hogs head. and put new control arm bushings on it, and painted it up. its ready to go.

 

i just got the transmission out of the donar yesterday, and noticed the shaft on the trans is much different than mine currently on my mj, i know this cause ive recently put a new slave cylinder on it. the shaft on the new trans has thick looking splines on it, and about an inch or so smaller shaft at the end. my dad said its cause the pilot bearings are different.

 

so question is

 

do i need to swap the pilot bearings before the reinstall? ive seen the grease trick to get them out

can i just buy a new one for the reinstall?

the clutch looked brand new in the donar, which is good cause the ba10/5 clutch is expensive. so ill prob use the clutch i took from the donar.

are the slave cylinders the same for the 2wd/4wd cause the slave cylinder was shot in the donar, but mine in my truck currently is only months old, could i just use it?

I'm going to clean the new trans up this week, what should i replace on it if anything? seals or whatnot.

is my d30 rear in the truck currently the same as the d30 in the 1989 xj donar i got? is there any reason i should swap the rear axel or are they the same. or are they geared differently beings the one in the xj was a 4x4.

 

 

any thoughts or ideas are greatly accepted, its going to be a few weeks before i do my swap, saving for parts, i plan on lifting it as well when i do it. so right now I'm prepping and cleaning parts i currently have, and making sure i have all the tools and resources needed to get the job done in a weekend. its vital due to its my daily driver and i have nothing else once its down.

 

thanks guys. marcus

 

 

[Pete M]

pics of the input shafts and such would help a lot  :thumbsup:  all the parts in and around the bellhousing should be the same 2wd vs 4wd.

[MancheKid86]

if the input shaft on the new one is bigger, pb 77 will do, the bushing style, 

[Jtrux]

Is yours a 2.5? I don't recall the spline count but a 2.5 has less spline than a 4.0.

 

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[th3m4nm4rcu5]

no my truck and the donar are both renix 4.0s. ill take some pics and show you what I'm talking about exactly. ill post tomarrow.