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My '96 ZJ 5.2 with AW4

Old 08-03-2016, 01:05 PM
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Default 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.























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Old 08-03-2016, 02:13 PM
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Sweet, well done.

How do you control the shifting of the AW4? TCU or manual/switches?
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Old 08-03-2016, 02:41 PM
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I installed TCU from XJ, it works the same like in XJ.
From engine you will need just TPS signal and brake signal.
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Old 08-04-2016, 08:01 AM
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No Check Engine light?
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Old 08-04-2016, 09:07 AM
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Pretty awesome!
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Old 08-04-2016, 10:16 AM
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It's funny because I expected check engine light (PCM controls trans in ZJ) however no check engine light at all.
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Old 08-04-2016, 11:39 AM
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Just to make sure it's clear how I created project in Autocad. First I made a pattern in wood




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




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.

Last edited by rgrosiak; 08-04-2016 at 11:49 AM.
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Old 08-04-2016, 11:49 AM
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Looks like you smoked an entire carton of cigarettes to create this thing lol!

Pretty cool though!
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Old 08-04-2016, 12:00 PM
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ha ha I expected this comment as also noticed it on the pictures.... but true, I smoked a lot ...
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