ok i have searched and searched. i have a 1994 XJ 4.0L, AW4, 231. that transfer case is shot and im trying to replace it. i bought a 1996 XJ 231 with the 1997 up style output shaft to replace it. im going to put a SYE in it. BUT, the input shafts are different lengths. from the mating surface of the tranfer case to the end of the input shaft measures 1.195" for the 1994 model and 1.365" for the 1996 model. does the 0.170" diffence matter? are the newer 1997+ AW4 transmissions and transmission output shaft a little different to accept this? i put some grears on the shafts and put the new tranfer case on to measure how far in it goes on the splines and its VERY close to hitting the non splined part of the transmission output shaft. has anybody put a 1997+ 231 on a 1994 or older?

 

http://www.novak-adapt.com/knowledge...nput_gears.htm

 

ya i had seen this when i searched but it says nothing about if i can leave the 1.365" late model short shaft and use it with my 1994 early style transmission? it bolts up fine but the splines are at the very end of the transmision outsput shaft where there are no more splines on it.

 

has anybody put a 1997+ 231 on a 1994 or older? :QUOTE:

or the other way around?

 

ya!! what he said! lol. i havent found any proof yet that anybody actually has. but i guess if all else fells i can turn down the input shaft but i dont really want to do that. i need a better way of measing while they are butted together. maybe a rubber band or something on the output shaft. the grease didnt mark very well.

 

The additional engagement is a good thing. More surface area means more strength.
Put 'em together and run it.

 

i aggree frankz, but if the splines are pushing on each other then it will wear out bearing quick! do you know if the AW4 transmissions were changed at all from the old to new style transfer case input shaft? i cant find any part numbers to veryify this.

 

To the best of my knowledge, no changes to the output shafts.