91 Comanche 4wd conversión

[Jeep_rlgn]

Hello JEEPS,

 

need some help. ASAP. 

 

I got a

1991 Comanche Pioneer 

4.0 high output 

5 spd 

2wd

 

runs like a charm! 140 k original miles. Some rust. Pully makes a noise, hard to shift sometimes after being warm. Gas leaks if more then 3/4 full and that’s it! 

 

Drove it from Indiana to Chicago. No problems at all! 

 

Then i I bought a 

2000 cherokee xj sport?

4.0 inline 6

automatic

4wd

 

my question is... can this be done? And what are the things that must be done for it to work. 

 

ALSO, I would like to keep my motor and 5spd tranny on the MJ. And just use axles, transfer case, and drive shafts if needed. From the donor XJ. 

 

I have attached some pictures. 

 

Pls tell me it’s possible and somewhat easy, inexpensive. Or am I asking too much? 

 

Thanks in advance. 

 

[Dzimm]

Welcome to the club!! 

 

4wd swap is not really hard, just time consuming.  First off The trans tailhousing is different so you can't use the 2wd trans with the transfer case.  You'll have to go to the aw4 which you can either use as an automatic or set it up with some relays and make it manually shifted 4 speed.

 

If you decide to ditch that 2wd transmission, post it for sale on here (classifieds will open after 10 posts), assuming it's the AX-15 (as it should be for your year), it should sell easy.  I'd actually be interested in it depending on price, I'm only a couple hours from you in Iowa.  

 

As for the axles, the front will bolt right up, the rear you will need to move the perches.  Post a picture of your MJ rear axle so we can identify it but I'm going to assume it is a Dana 35 as they are most common.  You will need to move the spring perches to the underside of the rear axle to mount in the MJ but it's fairly easy and that XJ axle is a C8.25 which is much stronger than a Dana 35.  Whatever you do, make sure your front and rear gear ratios match!  If they don't you will have major problems.

 

The front driveshaft will bolt up fine if you use the transmission, transfer case, and cross member from the XJ.  The rear shaft will need modified or replaced no matter what you do as the XJ is much shorter.

 

As for the gas tank, you appear to have a short wheel base truck based on your picture, you will need an 18 gallon tank which can be found on rock auto, Amazon, eBay, ECT.  Get a set of fuel tank straps as well as they will likely be rusted.  Not too expensive and could save you from a major fire.  

 

For your hard shifting, I'd first replace the trans oil and see what it does.  Make sure you use proper fluid as the brass synchros in an AX-15 will be eaten up if the wrong oil is used.  I personally use redline MT-90 in mine, curred some of my trans issues when I replaced it.

 

Be sure to start a build thread for your truck and add it to the registry!