96 ZJ OBDII AX-15 swap :D - JeepForum.com
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post #1 of 51 Old 10-27-2010, 10:27 PM Thread Starter
PurpleZJ
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96 ZJ OBDII AX-15 swap :D

well as some of you know i hate driving an automatic in my jeep/any vehicle and i now have to opportunity to change my transmission since i accidentally drowned my 42re last saturday. So i decided instead of rebuilding the transmission i hate having i'm going to do a 5 speed swap. I'm already making a tech thread since all the info is getting lost in my build thread already. at this point in time i am completely in the planning process since i'm trying to get a second job to finance the conversion. so far i have been referencing these threads as well as others
http://www.jeepsunlimited.com/forums....php?p=4628758

http://www.mallcrawlin.com/forum/sho...ght=speed+swap

http://www.jeepforum.com/forum/f13/o...d-swap-376096/

http://www.jeepforum.com/forum/f13/a...mplete-229778/

http://www.jeeps-offroad.com/showthread.php?t=23749

first here is the parts list i've gathered so far with prices
AX-15 from 96 XJ w/ 95,xxx miles from auto salvager-$400
AX-15 CPS for 96 XJ autozone-came with donor xj
AX-15 HD clutch kit 96 XJ autozone-used what came with xj(felt brand new)
Flywheel autozone-also came from donor xj
242 TCASE from 01 XJ(if sale works out)-$80
so far i'm at $846.98. still need xj clutch/brake pedals, shortened/lengthened driveshafts, a trann mount, and the clutch mc with slave cylinder(external). hoping to get everything as cheap as possible. if needed if i'm running the 242 or 231 since i'm gonna toss my 249 as well i'll will just get my rear ds redone to fit and rock 2wd until i can afford to have my front ds cut down and rebalanced. in the next week or two a member from my local club is going to help me trailer the jeep home so i can start taking her apart to prepare for the swap. any questions or advice let me know
UPDATED Prices of parts i've bought so far
-95 xj w/ ax-15/clutch/flywheel-$400
-slave cylinder/master cylinder/shifter
-xj clutch/brake pedal assembly- $20
-2001 xj 242 tcase- $80
Current total spent- $500
current total subtracted from it the money i've made so far parting out the xj
-sold tires/wheels-$150
-sold ac blower motor-$15
-sold front seats-$50
-front clip currently spoken for-no final price yet
-engine spoken for-no final price yet
$500-$215=285
so so far i'm into the swap for all of $285. if any of yal attempt this swap and have the ability/space i highly recommend buying a donor vehicle so you can take what you need and part out the rest to recoup your funds


1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
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post #2 of 51 Old 10-27-2010, 11:04 PM
JohnnyZJ
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good luck! i've researched this too, other things you need to source are a transfer case linkage to work with the ax in a ZJ. i think the only one that really works is off a ZJ.

good luck!

07' JKUR rollin on 35s
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post #3 of 51 Old 10-27-2010, 11:11 PM
ratmonkey
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Xj pedals don't work/need extensive modification to be even close. You need zj pedals.

'97 zj 5.2, some stuff, some other suff, and some things that even work sometimes.

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post #4 of 51 Old 10-27-2010, 11:21 PM
redfoxbody
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Yeah we have to find you some zj petals

Glad I listened to ratmonkey I almost went the xj petal route. But I think you'd rather bolt them in

1993zj made some out of xj petals im sure he could help you out if you couldn't find a set tho..

4.0 2x4>4x4 conversion 3.73, rubicon rims, 245/75R16 mtr 42RE > AX-15 Conversion in progress.
Build thread

Depressed about your car dent? dentszone.com


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Nice the legs in that last picture, almost makes you not think about the jeep.
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post #5 of 51 Old 10-28-2010, 08:47 AM Thread Starter
PurpleZJ
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Quote:
Originally Posted by redfoxbody View Post
Yeah we have to find you some zj petals

Glad I listened to ratmonkey I almost went the xj petal route. But I think you'd rather bolt them in

1993zj made some out of xj petals im sure he could help you out if you couldn't find a set tho..
I just pm'd 1993zj in hopes that he can take pictures of how he had to modify the xj pedals to fit. but it would be awesome to find a set of zj pedals. and as for the transfer case linkage i may just have to order the novak conversion kit, i just dont want to have to bend the shifter link myself since i dont have a torch.

1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
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post #6 of 51 Old 10-28-2010, 09:09 AM
gothchick
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Fun project. Good luck.
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post #7 of 51 Old 10-28-2010, 07:17 PM
ratmonkey
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Quote:
Originally Posted by PurpleZJ View Post
I just pm'd 1993zj in hopes that he can take pictures of how he had to modify the xj pedals to fit. but it would be awesome to find a set of zj pedals. and as for the transfer case linkage i may just have to order the novak conversion kit, i just dont want to have to bend the shifter link myself since i dont have a torch.
i didn't have to do any bending to get it through the stock location. you do have to trim it though.

'97 zj 5.2, some stuff, some other suff, and some things that even work sometimes.

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post #8 of 51 Old 11-02-2010, 08:01 PM Thread Starter
PurpleZJ
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Quote:
Originally Posted by ratmonkey View Post
i didn't have to do any bending to get it through the stock location. you do have to trim it though.
thats good to hear that i wont need to bend it. 150 is a little on the pricey side but heck if it makes it work i suppose its worth it. today while i was in kc for a dentist appointment i went and bought a 242 transfer case with about 70k on it. shifts through all the settings just fine and i tested the full time 4wd setting by spinning the input shaft by hand and holding the rear yoke still and then doing the same with the front. transfered my hand power both times. will post a pic in a bit. also anyone have good recommendations for a SYE kit? just another idea bouncing around in my head since i already have it out of the jeep. lol.as promised heres the picture of the 242

1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
PurpleZJ is offline  
post #9 of 51 Old 11-02-2010, 10:33 PM
redfoxbody
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Location: Sarasota, FL
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I wonder if a sye is even needed/helpful now that you are going to have a 3 inch longer rear driveshaft?

Oh and what year 242 is that? bc I think pre 96 has a bushing inside that you have to remove to allow it to slide on the output shaft all the way. I'm not 100% though

4.0 2x4>4x4 conversion 3.73, rubicon rims, 245/75R16 mtr 42RE > AX-15 Conversion in progress.
Build thread

Depressed about your car dent? dentszone.com


Quote:
Nice the legs in that last picture, almost makes you not think about the jeep.
Quote:
My 16 year old little sister, you creep.
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post #10 of 51 Old 11-02-2010, 10:39 PM Thread Starter
PurpleZJ
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1996 ZJ 
 
Join Date: Jan 2010
Location: kansas city
Posts: 4,197
yeah i was thinking that as well since its gonna be longer aka less driveline angle. and i kept the bushing thing in mind when looking its out of a 2001 XJ

1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
PurpleZJ is offline  
post #11 of 51 Old 11-22-2010, 03:25 PM Thread Starter
PurpleZJ
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Join Date: Jan 2010
Location: kansas city
Posts: 4,197
made some progress today. bought the clutch/brake pedal assembly from an xj for 20 bucks and went to work installing the pedals in my zj. enjoy
new and old

mount points difference

after trimming

manual pedal set

auto set. obvious difference in angles. so i got out the grinder and hammer

after modifying the clutch/brake pedal assembly. pretty much perfect

first of many cuts. should have gotten more pics of where i cut

side view

this kinda shows how much material i cut off. also cut a notch in the side so i could bend the top of the bracket to fit the contour of my zj

top shot of bracket

just gotta drill a hole for the top bolt

eyeballed with a punch and hammer for where to start drilling based on the imprint of the washer on the zj brake bracket. fit perfectly first try

hole i began to drill out for the clutch master cylinder. but i need a step-bit for the hole so that part has to wait

and the finished product. PERFECT fit with slight modification to the xj bracket

only thing i have to do is get a new brake plunger retainer clip and the pedals are good to go. plenty of space between gas/brake so i dont hit both at same time. brake and clutch are a little close but do-able. overall i'm pretty happy with how they fit. lemme know what ya think!
EDIT: forgot to mention. slight issue with brake sensor... zj one mounts in square hole while xj one has a round hole. and the plugs are different so i'll have to come up with a solution to that issue eventually...

1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
PurpleZJ is offline  
post #12 of 51 Old 11-22-2010, 03:57 PM
MurdaJs
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seems easier than finding unicorn blood

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post #13 of 51 Old 11-22-2010, 06:58 PM
StellaTheZJ
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Location: BC
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Can't wait to see the rest of your thread, as this is a very cool mod planned for my '96 too. Now about that PCM...
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post #14 of 51 Old 11-22-2010, 07:35 PM Thread Starter
PurpleZJ
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1996 ZJ 
 
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Location: kansas city
Posts: 4,197
only thing with the pcm is it not knowing wehre the tranny signals went so it shows a CEL. doesnt really cause any problems though. i'd like to find a way to solve that issue though

1996 ZJ- 4.0, AX-15 5SPD/NP242, RE 4.5" lift, 36x12.50x16.5 Goodyear military surplus tires, Longarms/Tri-4 link/one ton axle build/swap in progress, arb bumper, a bunch of other goodies
1995 XJ- 4.0 HO, ax-15(stolen for swap), stock
2001 GMC Sonoma-RIP...
2002 GMC Sierra 1500 ECSB-roadtrip/long haul vehicle
RIP Troy (bigbluezj94) you wont be forgotten

December 2010 GCOTM

5spd ZJ Club Member 001

Quote:
Originally Posted by bddisi View Post
Glad you are ok. If you were a cat, you would be down to 8.:D

Quote:
Originally Posted by Greengc4x4 View Post
Everything looks great, Hellen Keller! :D

Quote:
Originally Posted by rritch View Post
plastic + Fuel + Ignition = "Bubba wake up this is gonna be good" :rofl:

RIP William Anthony Kolich(DAD)
you were the best father i could have wished for. I'll always miss you
04/28/58-2/13/11
PurpleZJ is offline  
post #15 of 51 Old 11-22-2010, 09:55 PM
StellaTheZJ
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Location: BC
Posts: 629
I saved the pedals and bracket from when I parted out my 84 XJ, and your fabbing looks doable on the bracket. I've got the flywheel, clutch, and dust cover from a 1992 YJ, but I had to let go of the AX-15 recently... I can find another.

Is there no spark advance control or anything in the PCM that relies on the gear the tranny is in?
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