Hi, I'm a new 2001 XJ RWD owner today. My neighbor has had it for 10 years and its in great shape.

I am looking for a donor 4x4 and understand a 1997 and up would be ideal, but what about a 1996? I found one cheap. ( no motor or title).

Main reason to convert is to get a transfer case so I can tow behind my RV.

My question, Are there significant changes between the 1996 and 2001 that would make the driveline components not compatible?

Thanks,
Mike

 

It will all bolt together. But the transmission might give you some head aches. I believe they changed the plug for the electronics mid 96. 97 and up would be better. But if you are not afraid of taking your transmission apart and reassembling then go for it

 

Yes, The transmission will not work with the 2001 electronics. At least not without some significant work. You want 98+ for the trans swap.
See ==> https://www.naxja.org/forum/showthread.php?t=1053970

 

Thanks for the info. Looks like some issues with the tranny so I could take both to a shop and have the 2001 built with the 4x4 shaft.


The saga begins!

 

I did this. It's not terrible to do it yourself if you're careful. FYI, you cannot just chop the output shaft like I thought. The 2wd is 27 spline, and the 4wd is 23 spline. It won't work with the transfer case input.


Now, the NP241C might be an option. I've been itching to get my hands on a 27 spline input shaft from an NP241 to see if I can lop off a 2wd output shaft, change the extension housing, swap the input shafts, and have a 4wd for way less effort than a swap. Yeah, a bit of rambling, but it's something I've been working on.

Watch the video I linked to and you can see it's really not that hard. Also, once you get the 96 transmission torn down, there's your practice round. Tear the 2001 transmission down and you'll be a pro.

https://www.naxja.org/forum/showthread.php?t=1139417

 

why not just change the input shaft in the t-case to match your output shaft and bolt the t-case in without messing with anything else. just get the console and levers so you can shift from the seat so you can put it in neutral for now? if you don't plug in the 4x4 selector switch than the trans will still think its 2wd and everything will work. than once you know it will work, you can swap the front axle.

its not hard to swap the input gear. i have done it twice on wrangler 321 t-cases to put into zj grand Cherokees. i had never done it before and was anxious about it getting messed up but i did it on the back porch with normal hand tool. the worst part was getting some little piece to stay in while closing it up and it took me a few tries to get it to stay aligned and in place both times i have done this.

but it made lift a lot easier on the grand Cherokees, not having full time 4x4.

since you are in texas, where in texas are you? there is normally jeep clubs all over texas and we always used to have get togethers to install lifts or do motor swaps. if the person wasn't mechanical, they ran the bbq and everyone had a good time


edit: i got the input shaft off ebay from really cheap
edit 2: input gear or shaft. i cannot remember but i got the part on ebay

 

superj,

I believe the it is the output shaft which is longer in the transmission for the Tcase adapter. I could see changing the input shaft maybe possible to adapt to different transmissions.

My tranny has 197 K so I would likely have it rebuilt and built with a longer output shaft.

 

197k is not much for the transmission. but i see if they are already putting that longer shaft, might as well make sure everything else is good to go

 

The transmission output shaft is shorter in a 4wd transmission because the tail housing has the t/case mounting flange on it and is shorter than the long tail housing on a 2wd trans. You'll also need the driveshaft from a 4wd jeep as well. IDK about the AW4 trans, but the 42re found in the Grands has a separate O/D housing that unbolts so you don't have to pull the guts out of the trans to change the output shaft, just bolt on a 4wd O/D unit.

 

Thanks Dave,

Wasn't positive on the lengths, but I know they were different. The Chevy's were always longer