2wd to 4wd Swap

[CornFed]

I want to apologize for asking what had already been awnsered I'm sure of yet try as I might I can't find the awnser. I want to do a 4x4 swap onto my 2.5l Comanche. I'm trying to find a donor cherokee for both axles only. If I have to source an Ax5 for the 2.5l separately I will.

 

My question is what years can I use the axles out from under a Cherokee for the swap? I want as little work to do as possible so just unbolt and bolt up would be preferable. I know my rear drive shaft will have to be modified by a shop to fit and I'll have to find the front drive shaft with the Ax5. I do plan on continuing this thread when I inevitably do the swap. But I'd first like to find a donor jeep and I figure it'd be best to have it sitting in the field vs a Junkyard.

 

Edit to add because I'm stupid. I've currently got an 89 Comanche with the 2.5l Ax4 2wd short bed. Since I'm changing transmissions anyway I'm going to go from the 4 speed manual to the 5 speed manual. I know I can use an Ax15 but from slight browsing on here it seems that would be much more complicated. 

Edited November 28, 2021 by CornFed
ETA

[89 MJ]

If I were you, I would look at doing the following:

1. Source a non-CAD D30 out of an XJ with a 4 cyl (93-00 maybe? I need to be corrected on that). That will get you 4.10 gears and gets rid of the crappy CAD system. 
2. There are 2 ways you could go with this.
2.1 Source an 8.25 out of the same XJ, if it had an 8.25. 
2.2 Find a KJ Liberty with with 4.10 gears. This way will give you rear discs. 
Note for 2—you will need to weld spring perches on either way. 
3. Find your AX-5/231 or your AX-15/231/Dakota bellhousing. 
 

You will be able to use the stock XJ front driveshaft, but, as you know, your rear will have to be shortened. 

[Pete M]

you're definitely going to want 4.10 gears, as that new 5th gear will be mostly useless without it.    literally any year of XJ will work for you.  some years are better than others, but all can work.

 

 

[CornFed]

51 minutes ago, Pete M said:

you're definitely going to want 4.10 gears, as that new 5th gear will be mostly useless without it.    literally any year of XJ will work for you.  some years are better than others, but all can work.

 

 

In your opinion then what years would be better than others?

 

I'm going Junkyarding tomorrow because my passenger side manual window regulator broke today. So I'm going shopping and I might upgrade to power windows ain't sure yet.

[Pete M]

since you can swap late model shafts (with the bigger ujoints) into an early CAD axle pretty easily, they are all pretty much the same up to 2000 when they switched to low pinion.  but even that isn't really all that bad.  every single TJ has a low pinion front and they manage pretty well.   get an axle that appears to be in good shape and has 4.10s (unless you're planning on regearing)

 

do be sure to know what year the axle is.  while all years can be swapped in, the bearings and brakes and such changed here and there. 

 

 

[CornFed]

How can I easily tell what gear ratio is in an axle? I can't remember which axles is it most people on here say to avoid dumping money into?

 

Found a 95 cherokee being parted out. With Dana 30 front and rear under it. Depending on what gear ratio it has might get it. If it's recommended by yall on here.

[89 MJ]

No Cherokee (or any Jeep, IIRC, I know no XJs or MJs for sure) came with a D30 rear. It should probably be a Chrysler 8.25. That would be a good axle combo, but I’d only pick them up if they are 4.10s.
It would have come from the factory with 4.10s if it’s a 4cyl 5 speed rig. 4cyl autos had 4.56s, 4cyl 4 speeds has 3.55, 4.0 autos had 3.55s, and 4.0 5 speeds had 3.07s. Some XJs with the towing package had 3.73s, I’ve heard.

You will have to weld new spring perches on the XJ axle, but that will be the case with most axles. 

[CornFed]

Interesting ad says Dana 30s but I suppose it could be wrong. How hard is it gonna be to get 4.10s? 4cyl Jeeps aren't that common.

[Pete M]

every year of XJ had the dana 35 rear axle available.  a photo should clear that up quick.  

[CornFed]

Best photo I have from his ad. However he kinldy scared me off. He doesnt know what ratio is in either axle. When he got it the front axle was snapped in half.  So he went and grabbed another one from the Junkyard. Which concerns me because who knows if the ratios match.