prerunner xj build
 

Alrighty
I've got a 91 4door xj high output 4.0 with 5 speed ax15 trans.
So far I've done
Rc 4.5 lift with add a leaf with an additional 2inch coil spacer up front
Rc adj track bar with rc drop pitman arm
(BTW did anyone else have a hard time gettin that pitman arm on? I was struggling tightening it down and I know the splines were lined up)
Tires are 31x10.50R15 falken wildpeak a/t
Custom prerunner style bumper with 2 100watt Hellas
Custom roof rack with light bar with 5 kc daylighters and two dust lights in the rear
STILL TO COME:
Rear cage for some smooth body resevoir shocks
Fiberglass front fenders
Locker and gears
33s with some decent wheels (still rockin the stock jeep wheels lol )
Header
Attachment 364298
Attachment 364299

I'm calling it a "prerunner" build cuz It's only 2wd lol and Most of my offroading consists of open desert

Oh and it needs a long arm conversion with some new uppers

cool. im jealous yours is a 5 speed and mine isnt. although only 2wd sucks..

Haha I know, I can do a conversion but the money it would cost to do I would rather spend on just dialing in the suspension, engine, and some nice interior upgrades

Sub'd for another 2WD :gunsmilie:

there have been many of times when i really could have used 4wd, but now that i know my jeep's limitations i know how to enjoy just 2wd lol
i picked up this thing bone stock for $500 all it needed was a fuel pump
i love finding diamonds in the rough like this, previous owners that give up on their car and sell it for dirt cheap not realizing how simple of a repair the vehicle needs.

converting to 4wd
i have the d35 rear end with the ax15 5speed manual

correct me if im wrong, but all ill need is
d30 (do these have the same gear ratios as the rear axle?)
front driveshaft
either chop my rear driveshaft or just find one off a 4wd model
so my only question is what transfer case can i run on my ax15?


i know most ppl just say to sell it and buy a 4wd
but i cant find anyone who wants a 2wd jeep, and i've already put a lot of love and work into this thing i cant part with it, plus im a mechanic so i dont have any problem turning wrenches, i just wanted some of your guys' opinion on whether my above list is correct

you will need to change or rebuild you 2wd ax15 to be able to mount the 4wd tcase. and you should beable to find a front axle that matches maybe even upgrade to betteer ratio automatic 4wd inline 6s came with 3.55s some 4cl came with 3.73s and some also came with 4.10s. driveshafts come in differnt lengths you should be able to find one that works from a junk yard for cheap.

are there adapters available because im assuming spline counts are going to vary on the output shafts on my transmission?

really my only main concern is finding the tcase that works with my 2wd trans

if i were you id look for a 29 slpine 8.25. its still a bolt in replacment and a much better rear axle than the dana 35

all you have to change on the ax15 2wd is the output shaft and tail housing.

Are there any specific tcase models you guys would recommend for my transmission?

I'm picking up a d30 for $85 on Wednesday, for now ill just stick to stock d30/d35 since this is really my first time dealing with something 4wd

Any 231 from a 91 or newer should be fine
What year is the D30 out of?

The np231 are 23 spline right?
And I'm not sure but I know its a 3.07 which is the same as my rear end

Just texted him its out of an 89

ok so say i pull my trans
split the cases
remove the syncros gears countershaft mainshaft etc.
all i need to do is replace that output shaft with the appropriate one to work with a 231 tcase?
will all my syncros and gears etc. all still work with the upgraded 4wd intended output shaft?

let me shorten that last post

take a 4wd ax15 and swap it out! lol only problem is i know 5speed 4x4 are hard to find
maybe i can find just the shaft online or from a transmission shop

Your gonna be better off with a new tranny and TC IMO... not worth the hassle if they're already bolted together and ready to go

whimp you wont jump this thing and take a video of it for all of us to see haha.... no but really it looks like an interesting build ,,,sub'd

I would recomend take you time and do it right once sometimes people get in to big of a hurry and mess things up.

you have plans to truss the hell out of your axles yet? not enough pre runner xj's on this forum I'm glad to see it
but you've got a looong way to go before that thing can jump

To be honest, at first I was going for a prerunner theme, I still kind of am as far as looks and how I intend to off road in it, but let's be honest, 2wd jeep is like drinking non alcoholic beer, unless u go with twin I beams up front then ok maybe lol

This thing is still in the baby stages with what I want to do with it. I still have plans of making it to jeepspeed specs, just would be nice to have it 4wd capable as well.

After all my research today, I found just a new ax15 4wd output shaft would be over $100
If I go to pick a part on half off say I can get a trans with tc for $150 with warranty lol

Ok now help me out here guys, I read I can find 4wd ax15s in dakotas and durangos? If this is true what years and wat models? Obviously the bell housings will be different but I can just swap the one thats on my trans

And ill take a video of my jumping it next time I'm in lucerne lol I've jumped it a few times, not "HUCKED" it but definitely have caught air in it before lol

putting that thing in the air is a gamble every time. as for the trans/tcase god I hate messing with that stuff
I'm a quitter I'd just buy a new jeep that has the stock specs you like

And yes you are too right, my welded on roof rack is a perfect example of rushing and messing up lol

I kind of want my jeep to be a little more of a "go fast jeep" and for that I would think you'd want a np242 tcase. The full time will give you traction in the straights and then if you need to turn it unlocks the hubs making it slightly easier to turn. I believe it has a 48/52 power split so if you tried hard enough you could probably still get the rear wheels to pop out around a turn. But I really don't know much about prerunner jeeps and stuff like that.

Lol jeeps just weren't meant to grow wings, but its undeniably fun to get away with it! Lol

Really? I love trial and error stuff, seeing what works and what doesn't, I think its more of a "keep me busy" thing, yes I could just sell it and buy a 4wd but then ill never know what it would be like to have a big project like that. Idk I'm in no hurry to have this thing fully built so I figure ill just experiment and try making lemonade with lemons man

Yeah I read about that, but sounds like there would be electronics or some sort of ecu involved to control that?

Uhhh I have no clue how it works hahah. I just know when I turn in full time on the street or dirt the front tires don't lurch and jump like how they would in 4hi or lo.
Anyways good luck with the build! And I like your roof rack. It gives it that prerunner vibe

Lol thanks dude, I'm redoing the roofrack to make it removable, fab up some sort of bolt on design but not too sure if I wanna invest my time in it till I get the motivation to remove it and clean up the roof a bit, u can imagine how beat my roof looks from welding on my mounting points lol

Ok so to broaden my search at pick a part I'm not only looking at Cherokees but gonna be looking for 3rd gen dakotas that had the ax15 4wd as well, hopefully one with an internal slave cylinder like mine, but if I find one with an external slave can I still make it work?

Actually couldn't I also look at certain year wranglers?

I don't think anyone's mentioned that the 89 front axle may or may not have the vacuum disconnect. If so some modification would be required to make it work correctly.

How do I know I'm getting a correct axle?

1993+ is non vac. 1995-1999 all have bigger ujoints. those are the best ones

right on ill remember that, thanks

this axle did have the vacuum so i passed
my main objective right now should be to find a trans/tc anyways, axle and drivelines etc wont be as difficult to hunt down

i hear the d35 isnt a good choice of axle if u plan on running a locker? unless u go with the superior axles' super35 kit?

recommendations? ill mention now i dont plan on abusing this thing off road every week, i usually only make an offroad trip once a month to the desert, so i dont want to "overbuild" something but at the same time dont want to settle for "decent"

The dana 35 is a weak axle upgrade to a 97 and up 8.25 bolts right up and has larger axle tubes and bigger shafts and for a tranny keep looking on craigslist one will pop up i literaly searched craigslist for 2 seconds one night out of boredom found a 95 xj 5 speed 4 wheel drive drove it home next day and swapped my auto for the manual

That's awesome lol ill keep searching haha

Yeah I was considering either a 8.25 or a d44
So u guys recommend upgrading the rear axle before goin 4wd then huh