JeepersCreepers

Ok I got a great deal on a 4x4 swap for my 2wd Cherokee. Heres the list below of what he gave me.

Complete Front Axle
231J Transfer Case
Gear Selector Handle & Center Console Panel
Transfer Case Mount & Cross Member
Front & Rear Drive Shafts
Transfer Case Wiring Harness
All For $240.00

He has a fleet of 4x4 Cherokees for his business so he was parting out one of them. Now I know I'm missing a transmission but the guy is giving me a couple of slipping 4x4 transmission so I can rebuild into one. Great Deal for $240.00.

Now I have a couple of questions.
1. Do I have everything or am I missing anything for a COMPLETE swap?
2. Where can I find a diagram so I can rebuild this transmission?
3. Where does the vacuum line off the front differential go?

Thanks For Your Help!

BlueXJ

1- sounds pretty complete.
2- No ideas on where to find a guide for this project. That is the only thing I would farm out.
3- To the transfer case if you retain the vacuum disco setup.

JeepersCreepers

so that vacuum line goes straight to the transfer case. does it split off into anything or is it one line. do i have to hook it up.

OverlandZJ

What year did the donor parts come from?

I second having a trans shop doing the rebuild, or you could find a used replacement for 1/4 of the cost.

Is the gear ratio in the front axle a matching ratio for the rear?

I personally removed a vacuum assembly from a YJ CAD axle assembly when i installed a "posi-lock", there were other lines going to the intake manifold and some other "do-dads" in the harness. Blue may be correct that all it needs is vac from the transfer though... i'm not sure on that issue. Personally, i'd have opted for a non-disconnect axle assembly.

COSXJFAN

Get the Posi-Lock system for your CAD. I had it on my 89 and it was flawless!! It makes it possible to have 2low, as well as, 4 low. It's about the best thing that you can do with a cad axle, aside from throwing it away!! HTH!!

BlueXJ

The vacuum line is T'd off of to provide the vaccum needed to hook up the disco. The transfer case signals that to the disco when it engages 4WD. so the vacuum needs a signal from the tc to engage the front axle. A posi-lok is much more efficent than the vacuum system but it is all manual so you will have to think about the steps involved when you shift to 4WD.

JeepersCreepers

The Donor Cherokee is a 96. The front axle the same gear ratio. Right now im trying to get it to factory 4x4 and then go from there. So the vacuum line goes from the axle to the transfer cases and t's off to the intake manifold?

87xjco

There's actually 3 hoses at the transfer case switch, 1 is manifold vacuum, the other two go to the front axle, depending on what gear the transfer case is in , one vacuum hose applies vaccum to the left most vacuum fitting on the axle vacuum motor and moves the shift fork in the axle one direction to engage the front axle, the third hose applies vacuum to the right most fitting on the axle vacuum motor and moves the shift fork in the other direction to disengage, IIRC there is a 3rd (middle) vacuum hose on the axle vacuum motor, I believe it goes to a firewall switch for the dash indicator.

Teed into the manifold vacuum hose is the vacuum resevoir that is mounted behind the front bumper and there are check valves and tees that confuse the vacuum hose routing of that system somewhat..... o/k alot!

OverlandZJ

I dont think that transfer case will have a vacuum port for the transfer as the CAD wasnt available in 96. I believe you can install one however.

Blue is more familiar than i on the vacuum plumbing...

JeepersCreepers

is there a diagram for this online somewhere.

BlueXJ

This Renix one is all I have and it is a PDF format.
http://jeepgarage.free.fr/OWN/vacuum%20diagrams.pdf

JeepersCreepers

It doesnt show anything about the transfer case or axle.

BlueXJ

Sry that is my only one.
Blue

JeepersCreepers

I wish i knew someone with a 4x4 cherokee.

BlueXJ

JC do you have a FSM they probably have what you need in that.