Another 2WD to 4x4 conversion question
 

Vehicle is a 89 MJ. Figured that that's irrelevant since it's the same issue from MJ to XJ. Anyways, I have high pinion D30's readily available. I just scored the console and shifter out of a 4x4 XJ. My issue is with the trans. If I go with a 89 tranny, it's still going to be the smaller output and I'm still going to have to look for that year T case. If I was to try to swap the tailhousings and tailshafts, couldn't I swap to the bigger output shaft and use the 92+ transfer case? It doesn't seem to be a huge undertaking to swap out output shafts on a AW4 according to what I'm finding on here and google. Any input on this guys? Also, anybody have a link to the break down of the AW4? I saw it on here once but can't seem to find it now.

21 spline 231s are not hard to find.. I've never seen anybody break an output shaft before something else. So not seeing the issue. Swapping the tailshaft is not an easy undertaking.