My '95 ZJ looks like the transmission may need to be replaced soon. I was just wondering if it is possible, and if so what am I looking at to do it, to switch out the 42RE automatic with a manual transmission (AX15). And I believe I have a NP231 transfer case. I prefer manuals and would rather take the auto out and put the manual in, but I have not done that involved before and the clutch will also have to be added, and whatever modifications would be needed for the shift stick. I was also wondering if it would be worth it. If not I will have to look into getting a rebuild 42RE at some point. Has anyone done that before? Thanks! - Jeremy
I'd be doing the same , swap in a 5 spd . You would think you need a PCM , BCM and/or TCM from a 93-94 . That's the big obstacle . I'm not sure what the system would do if you just swapped in the gearbox , might be just a CEL . That's fixed easy enough , yank it out , lol .
The slave cyl just mounts on the gearbox , so all you would need is to mount the reservoir which is simple .
Ideally , you found a ZJ manual donor , the pedals would be a bonus . Pretty sure you could make something from a XJ work with some modifications .
You may or may not need a crossmember . If you need any measurements off an AX-15 to compare , let me know . I have one out of 94 ZJ in my garage
There's probably a patch panel in the floor for manual transmissions . Remove ot or just cut a hole . Toploader gearboxes don't need much
Thanks for the reply. I seem to be in the habit of posting messages before googleing After a little searching it looks like it is very possible. From what I read you do not need to replace the computer but will need the crankshaft position sensor replaced. Also the drive shafts will need to be adjusted by 3". Everyone showed you would have to punch in hole. I guess the pedals on a XJ will fit the stock brackets if you cannot find a ZJ. I found a post that did this -
He has the prices listed so I guess if you can find the parts, it is a lot cheaper that replacing the automatic. We have a lot of auto salvage places around here so I was going to call around and see what I can find. Thanks! - Jeremy
Ratmankey, one of the mods here, has the complete write up in his sig. Find a thread where he posted, not too hard, and read his sig.
1994 Grand Cherokee Limited 5.2L V8 318, Spectre cold air intake, Flowmaster Super44 muffler to 3.5" resonator tip, 30x9.5 BFG A/T's, Custom Tranny and TC shifter mod
My Build Thread--not sure how to make that the link-http://www.jeepforum.com/forum/f13/my-build-thread-1568707/
Its not easy it's a lot of work and a lot of money find a donor xj and use all the parts and you have to do some fabrication to the pedal brackets, I'd look for a pre 94 xj yes everyone says do post 94 but for a slave cylinder it's like a $300 savings and plus there's more pre 94 Cherokees out there
on an earlier model its not that much work comparing to rebuilding a trans.
youll need some patience though
flywheel dust cover
correct crank position sensor
zj clutch master cylinder is definitely easier, i used the xj one
pedals, good luck finding them from a zj, i made mine from the factory bracket and the xj bracket with xj pedals
xj shifter works pretty well, i bent mine a lil to put it where i wanted it
tj inner shift boot works well
transmission preferrably with external slave, youll have a plumbing mess with the zj master if you try internal
transfer case of your choice
28.5" front driveshaft
36" rear driveshaft, which i have a nice beefy extra if anyones looking to do the swap
93-95 you can buy the oem trans mount from a local parts store, newer youll have to find the older crossmember or fab one, if youll be wheeling much i suggest just building one along with installing some hd motor mounts
cut a hole where your shifter used to be
transfercase linkage will need modified cut and lenghten/ shorted as necessary i cant remember which because i put a novak shifter in mine, i may have the heim joint rod i used originally
wiring with obd1 (93-95) is easy kill power to trans ecm, ground for neutral/ clutch safety switch to ecm and reverse lights
finish the interior to your liking