elzey829

just bought a 1986 2wd comanche. found a front diff, transfer case, and front drive shaft for $250. Just wonderin what all i would need to convert it to 4wd. thanks in advance for any help.

BlueXJ

May I suggest that it is not difficult to do as I have done it on a 96 but there is a member who is going through the conversion right now. You should read his posts and PM him for any additional info. He is Jeepers Creepers.

JeepersCreepers

Someone called my name! The 4wd conversion isnt that hard to do. The things I found you will need is listed below.

1. Front Differential
2. Transfer Case
3. 4wd Transmission
4. 4wd Transmission Wiring Harness
5. Shift Linkage For Transfer Case
6. Shifter and Bezal For Interior
7. Front and Rear Drive Shafts
8. And All The Nuts And Bolts For Everything

Now Its not has hard as it looks. You have to have patients when pulling in the transmission or else you can damage something. Im alomst done with my convertion. I just have to hook up the shift linkage and Im done. If you have any questions feel free to PM me.

BlueXJ

See I knew you were the man for this question. A fresh memory and a fresh perspective too.

JeepersCreepers

Ya And I pulled parts from many different vehicles. Alot of help came from you Blue.

SaintSabastian

I have an 87 Comanche that I will be doing the same thing to. I have a qq about the transmission.
My Jeep only has 90k on it so the engine/trans are in perfect shape. It's the 4.0 engine with the auto trans. What is the reason for the 4wd trans? Is there any way to salvage the one I have during the conversion. I hate to throw away a 90k trans for a 200k 4wd trans if I don't have to...

Thanks for the info, can't wait to start my conversion...

Metmknice

The tailshaft housing is different, for 2wd its extended almost cone shaped. and the 4WD is not as long and has a flat surface to mate the t-case to. I am not sure if you can swap a tailshaft housing from one to the other tho.

taythegibs

would it be much harder for a couple of people w/ a 2000 cherokee??

OverlandZJ

I converted my XJ to 4WD years ago. Not a bad job at all.

The transmission which is an AW-4 automatic has a longer rear output shaft when compared to the 4WD version. About 7" longer, cutting the 2WD shaft wont work because of spline and speedo gear issues.

You could swap a 4wd output shaft into your 2wd trans... but thats alot of work. The AW-4's are pretty stout units, many running with 250K miles or more still.

SaintSabastian

Thanks for the info. Looks like I can get a trans from Pull A Part here in Charlotte for about $40 so I will just pick one up. At least I will have the original if I need parts...

JeepCoMJ

to the OP

make sure that you have a transmission that's ONLY for the 2.5 4 cylinder, or 2.8 6 cylinder jeep. 4.0 transmissions are not interchangeable without a TON of adaptation and parts you don't have/are hard to get.

the swap itself is easy. put in the front axle (it's all the same mounting, so bolt-in), swap in the transmission (as long as you're staying with the same transmission but 4wd version, it's bolt-in), mount the shift linkage (there's a blockoff plate on the transmission tunnel for the 4wd shifter) and transfercase, install the driveshafts, and away you go.

now is the time to lift the front end, and install a new clutch (if it's 5 speed) and slave cylinder. with your setup, try and go with the external slave cylinder. IIRC your 86 should have external, so swap that bellhousing and clutch throwout plate onto the new transmission.

as for reason to swap transmissions, the tailshaft housing is different, and the tailshaft is much, much longer. if you wanted to swap them, you'd have to tear apart the transmission.
here's a pic of an ax5 5 speed 4wd tailshaft vs a 2wd one. I swap tailshafts now, because I have alot of 2wd transmissions and I keep blowing the 4wd ones
this is a 4wd one

and this is a 2wd one


sorry but there's no side-by-side. you should be able to see the difference.

btw, I have a longbed 4wd 4 cylinder rear driveshaft that I would sell you

-Pat

OverlandZJ

JeepCoMJ

I totally missed the year and 2.5 details. You do not have an AW=4 trans OP.

black97xj

Hi everyone I have a donor 89 limited 4x4 automatic 4.0 will the drive train from it fit a 97 2wd 5spd 4.0 as easy as bolt on for my 4wd conversion? thanks, black97xj

JeepCoMJ

you should probably start a new thread.

the answer is no, it is not plug and play and go. yes, it will physically bolt in, but you have to swap the ENTIRE wiring harness to make the 97 motor run, the ENTIRE interior, all accessories, even the gas tank. it's a complete swap.

I'm in the middle of doing a 95 H.O. 4.0 conversion in my 87 4.0 jeep comanche...there is nothing left from the comanche's running system.

black97xj

i want to keep the H.0 motor in the 97. just wanted to know if the front axle, trans, tranfer case, drive shafts, ect.. from the 89 would bolt up to the 97 and work. from what i read if i put the auto trans from the 89 in the 97 the computer in the 97 would not operate it because the computer in the 97 now is for the 5 spd. thanks for the info.

I posted a new thread black97xj 2wd conversion to 4wd