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-   -   My '96 ZJ 5.2 with AW4 (https://www.cherokeeforum.com/f91/my-96-zj-5-2-aw4-227675/)

rgrosiak 08-03-2016 01:05 PM

My '96 ZJ 5.2 with AW4
 
Hi guys,
just wanted to show you my ZJ 5.2 with AW4 modificaction I made.
Some pictures below, complete story and how I did it under this link
http://jeep.org.pl/forum/thread-62884.html

If someone would need it I stored dxf files I created to burn (by plasma or laser) this special part to fit AW4 into 5.2 engine. Also this project needs torque converter modifiction, everything I described on link above, you probably will need google translator as it's in polish :)
Everything works great and hopefully any problems with tranny went away forever.



https://cimg7.ibsrv.net/gimg/www.che...964fa52e17.jpg

https://cimg1.ibsrv.net/gimg/www.che...0a0a466831.jpg

https://cimg4.ibsrv.net/gimg/www.che...321b4cc71e.jpg

https://cimg6.ibsrv.net/gimg/www.che...6f7bc76eb0.jpg

https://cimg7.ibsrv.net/gimg/www.che...44b43bb74e.jpg

https://cimg8.ibsrv.net/gimg/www.che...a5c51e806c.jpg

https://cimg1.ibsrv.net/gimg/www.che...bd021686a7.jpg

https://cimg8.ibsrv.net/gimg/www.che...e724ff28e5.jpg

https://cimg8.ibsrv.net/gimg/www.che...02a8e780e3.jpg

https://cimg4.ibsrv.net/gimg/www.che...56b9a21781.jpg

https://cimg5.ibsrv.net/gimg/www.che...e44c709c90.jpg

CobraMarty 08-03-2016 02:13 PM

Sweet, well done.

How do you control the shifting of the AW4? TCU or manual/switches?

rgrosiak 08-03-2016 02:41 PM

I installed TCU from XJ, it works the same like in XJ.
From engine you will need just TPS signal and brake signal.

OverlandZJ 08-04-2016 08:01 AM

No Check Engine light?

Bustedback 08-04-2016 09:07 AM

Pretty awesome!

rgrosiak 08-04-2016 10:16 AM

It's funny because I expected check engine light (PCM controls trans in ZJ) however no check engine light at all.

rgrosiak 08-04-2016 11:39 AM

Just to make sure it's clear how I created project in Autocad. First I made a pattern in wood :)


https://cimg0.ibsrv.net/gimg/www.che...37471b2305.jpg

Then I scanned wood pattern with 1:1 scale into Tiff format.


https://cimg7.ibsrv.net/gimg/www.che...791267f255.jpg

So having this I could easily create Autocad project in order to burn it with CNC plasma, I made it from 4 layers 5mm and 1 layer 8mm, in summary 28mm.

To be honest it was 90% of entire effort needed to make this project happen. Of course burned plate is not plug&play, a lot of hols must be drilled because plasma will never do it with enough quality however it's easy anyway.

Jeepin'_Aint_EZ 08-04-2016 11:49 AM

Looks like you smoked an entire carton of cigarettes to create this thing lol!

Pretty cool though!

rgrosiak 08-04-2016 12:00 PM

ha ha :) I expected this comment as also noticed it on the pictures.... but true, I smoked a lot ...

Dennis Finke 04-25-2020 12:48 PM

Did you have to change driveshaft or torque converter


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