A few years back I finally pulled the trigger and yanked a well-loved AX15 from the local pick and pull.
Lots of parts, a full rebuild and install later and the 2000 XJ build looks like it came from the factory with an AX15 / manual trans.
Even the shift light now works on the gauge cluster 😎 🧰





Wanted to compile some takeaways and especially a parts list from the build.
Most all of the donor parts came from a 1998 Cherokee - and all installed into my 2000 Cherokee over a few weeks time.




Out with the old (Clapped Out AW4) in with the new (rebuilt AX15)


First test run on the new manual swapped setup - San Diego to San Luis Obispo (~300mi)

 

Complete XJ AX15 Swap Parts List:

Yanking the donor parts from the pick and pull meant one chance to get it right.
I pulled everything I could think of that differed from my automatic factory XJ to the manual donor.
Glad I did - as there's lots of little parts to make things work as they were designed.






Sourced From Manual Transmission Donor Cherokee:

XJ Manual Transmission: AX15 (Pref. 1994-1999)
(Complete with transmission, bellhousing, shifter assembly, hardware & reverse light switch)

XJ Transfer Case (Matching NP231/Manual Spec)

Manual Trans Front Driveshaft (Length Is different Than Automatic)

Rear Driveshaft (Rec. Aftermarket Upgrade To Double Cardan DriveShaft)

Manual Donor Crossmember & Transmission Mount

Cherokee Pedal Assembly W/ Clutch Pedal (Clutch/Brake Combined Assembly)

Clutch Assembly, Master & Slave Cylinder

Throwout Bearing & Shift Fork Assembly

Flywheel, Flywheel Hardware, Flywheel Cover, Etc.

Steering Column (May be able to modify Auto column to work)

Interior Shift Boot/Trim Fitting

Manual Transmission PCM/ECU (Needs to Match Your Vehicle’s Year & Reflash For 5-Spd)



Replacement/Service Parts:
Transmission Mount, AX15 Rebuild Kit, Proper Pilot Bearing, NP231 Rebuild Kit, Clutch Kit, Master & Slave Cylinder Kit, Ax15 Oil (10W-30), NP231 Transfer Case Fluid (ATF+4), Gaskets & Tube of Gasket Maker.
Replacement shift boot, shift ****, as needed.





Aftermarket/Upgrade Parts:
Rear Driveshaft - Double Cardan Upgrade

Slip Yoke Eliminator Install (Recommend for all lifted / 4x4 builds)

 

After sourcing all the swap parts - I decided on a full garage rebuild of the AX15.
It shifted fine at the junkyard, spinning the input shaft by hand, but teardown revealed expected wear on the clutch, syncros, etc.




I have some more info on the craftsman collaborative site about the rebuild as well as the complete photo gallery of each AX15 Rebuild part/process, so I'll just put a recap here and get back to the swap.

The whole transmission can be built over a few days/week in the garage depending on experience and how detailed you get.
As a first time transmission rebuild for myself, I labeled every part, took before and after pictures to troubleshoot (note the full gallery above), and kept parts stacked in an organizing bin until it as time to reinstall.

There were a few manuals/articles and a youtube series I followed that made the step-by-step process easy to follow - I can try and pull those up and link them too.





In short, you strip the AX15 down to the gear columns, break them apart with a shop press, replace the syncros, inspect the gears, and press the assembly back together.
Check clearances with a feeler gauge all around, and continue onto reassembly. I found no gear issues/wear that stood out - so the full rebuild kit I purchased covered the majority of rebuild parts.
Once the gears, syncros and shifter assembly was buttoned up, I tested it for clearances and proper movement one last time, then bolted the cases back together and went for install on the Cherokee.

 

You are kind of a legend dude. This is the dream.

 

Next came install:

- Mating/bolting up AX15 and clutch assembly to the 4.0
- Installing the reflashed OEM PCM assembly
- Double checking and rerouting wiring/grounds for the NSS and other circuits
- Installing new shift boot and interior trim/pieces.
- Pedal Assembly Swap
- Steering Column Modification/Cable Removal
- TCM removal
And a few more steps to match everything up to an OEM AX15 build/specs

Compiled some more in-depth info on the AX!%, rebuild and cherokee manual swap here:
https://craftsmancollab.com/ax15-swap-jeep-cherokee/

Any missing info / questions - give me a shout here!

 

I always appreciate more info out there on this swap. I've got my clutch pedal installed already, I just need a driveshaft and crossmember (or drop brackets... bleh) to do my swap. The transmission being an unknown unit has me hesitating to swap it as well, maybe I need to follow in your footsteps and rebuild it while it's out.

Biggest issue though is finding the time.

 

The rebuild wasn't as bad as I thought - but it is definitely best to go start to finish before parts get scattered.
Lots of sharpie/tape and ziplock bags made for an easy teardown and rebuild.

Watched it on repeat a few times and made it much easier knowing what I was getting into.

 

Wanted to add some more info on the AX15 rebuild - put together a tech writeup full of details and references to the better rebuild videos and materials.

It's easy to get lost in the details, but reading through with good pictures, watching the linked videos and printing out the factory service manual makes the job much easier to plan for.

https://craftsmancollab.com/ax15-reb...by-step-guide/

 

Again, thank you so much for posting this. I don't even know how many miles are on my transmission, so a rebuild would make me feel a lot better about removing a perfectly functioning AW4. I hope to find the time soon but your write up has given me a lot of encouragement.