'98 ZJ Five-Speed Swap
I hadn't actually intended on doing a full write-up, but my ZJ being a '98 caused some issues that you wouldn't face on a '93-'95, and I took quite a few pictures, so here is where I ended up. I had planned on doing a 5-speed swap since I saw Woody's, but I had just had the 42RE rebuilt, so I didn't want to spend the money twice. Shortly after the rebuilt trans hit the 1,500-mile mark, it puked out all of the fluid, and the O/D went out on it. Rather than have it rebuilt again, I embarked on the swap. Here's my lovely ZJ before the swap:
First off, nearly all of the parts are the same as in an OBDI swap, with the exception of a few parts. Just for reference, the parts I used are listed below:
NAPA Clutch part no. MU1890-1D
NAPA Flywheel 50-1002
NAPA CPS CSS613
'94 ZJ 5-spd pedals and shifter with boots (thanks, Gunthagunth)
JeepShop.com '94 ZJ clutch master and slave cylinder, pre-bled
Tom Woods front and rear driveshafts (haven't ordered the front yet)
AX-15 out of a '94 XJ 4x4 with 68k
There are no trans mounts or combination thereof that let the AX-15 bolt into my '98. The '95-under AX-15 mount has a fore-aft bolt orientation, whereas the '96-up use a side-to-side. There was a TSB to convert the earlier autos to this setup, but it wasn't performed on the 5-speed (go figure). You may be able to use a '95-under crossmember with the correct mount, but I just stuck with my stock one. I did order up Rockauto for a '94 ZJ 5-speed, then took the 42RE and AX-15 mounts to a fab shop, and had something made that worked. I didn't take any pics of it, but one of these days I'll pull it out and do so.
42RE vs AX-15 mount:
The brake pedal bracket out of the '94 would not fit in my '98. In the end, I simply swapped the pedals themselves, and reused the stock '98 bracket.
The holes for the clutch pedal and master are marked but not drilled. Drilling them was relatively easy, though getting the angles right is nearly impossible. As a result, my pedal sits about a 1/2" too low, definitely not worth worrying about, though I may lengthen the bolt holes and fix it sometime in the future. Also, there are two spots for studs on the top of the clutch pedal bracket, but the studs weren't there on my '98. They would have ensured the correct angle of the pedal bracket, but don't seem to make a difference in strength.
On the same note, the wiring harness ran right where the clutch pedal needed to go. It was easy to move out of the way once the pedal was in, but something to watch out for when drilling.
On the firewall there was some unused mounting locations right behind where the clutch pedal went. As a result, the studs on the pedal bracket wouldn't stick far enough through to mount the master. A metal chisel and hammer made quick work of them however.
The CPS I bought has a completely different connector than my '98. I read on another write-up someone with a '96 using it, so they must changed the connector some time since then.
I don't have a soldering gun, so I cut off both connectors, and wired the '98 connector onto the new CPS. I used butt connectors, put heat shrink over the top, and then wrapped the entire thing in electrical tape. Not the greatest setup, but works well enough for me. You have to ensure you hook the right wires up though, because the wires are all black, with the middle one having a white or gray stripe.