2.5 ax4 2wd to 4wd

[Comancheche]

So I have looked all over to try to find this answer but can’t seem to have any luck. I have an 89 2.5l 4 speed 2wd that I’m thinking of switching to 4wd. Not a rock crawler just something to get around in bad weather. My question is what would I need to keep it 2.5 and the 4 speed and do the conversion? I know I’ll need a transfer case (np207?) front drive shaft. But what else? Thanks

[Jeep Driver]

Transmission, TC, front DS, rear DS, 4x shifter, front axle geared the same as rear axle. 

 

And a myriad of suspension and steering parts that you'll want to or need to replace. 

 

 

FWIW- look long and hard, high and low........these parts are getting harder and harder to find.

Most of us will look for donors, a '94 XJ is a good donor for your, however, finding a good 2.5 donor is getting near impossible now.

[dasbulliwagen]

don't count out 86 models with the 2.8 as a donor, as the trans is external slave and most had better axle gearing than your 3:55 and it will bolt right up to the 2.5 and still has the hole for the crank sensor. Though with all the correct parts, later AX4/5 with internal slave can be converted to external slave setup. 

 

Is there any reason you want to stay 4 speed? They are out there in 4x4, but are much rarer than a 5 speed. The 5 speed is identical externally to the 4 speed just FYI.

[Eagle]

The NP 231 is a much better transfer case than the NP 207, but you have to be sure the one you get has the same spline count as your transmission. Considering that you can't just bolt a transfer case to a 2WD transmission, IMHO you're far ahead of the game if you buy an AX-5 5-speed transmission and transfer case together. The AX-4 and AX-5 are the same for the first four speeds and reverse, so you could keep the AX-4 for spare parts.

 

In addition to a front driveshaft, the transfer case obviously adds a lot of length behind the transmission, so you will either need a different rear driveshaft, or you'll have to have your driveshaft shortened.

[benjy_26]

Do what I did; get the trans and t case from a YJ. A 5 speed will have the same ratios as your 4 speed anyway. You'll just have the option of using overdrive on the flats.