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Unread 12-28-2011, 08:45 PM   #1
ymurf
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Official 4.0 AX-15 swap thread

Well guys I have started the 4.0 swap into my CJ7. Will try to document everything and take lots of pictures as I go. I have learned allot from you guys on here so far.This is my first Jeep. First off My jeep has a CJ7 frame and front clip and a YJ tub.It has the 258 with 3 speed right now. Everything I am swapping to is out of a 1994 rolled YJ. I am swapping the 4.0 with MPFI..The AX-15. I bought a Dana 300 to use in the swap.I am also swapping the hydraulic clutch as my tub has the holes for it anyway.Also the power brakes.My steering is a little loose so I am also using the YJ steering box and tilt column.Shaft it allot tighter than mine is.Things I still need are the clocking ring, A speed sensor for the transfer case from a 1991 YJ. And I need to find a clutch fan cause when they rolled the YJ fan hit radiator and bent one blade pretty bad.They also broke the NP231 transfer case as you can see in the picture.Good thing I didnt need that.Here are some pics of my first nights progress.


And now with no front clip.


Motor and AX-15 I am putting in.

Busted NP231 I removed.


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Unread 12-28-2011, 09:05 PM   #2
MoC
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Lol my name is in your license plate!
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Unread 12-28-2011, 09:11 PM   #3
ymurf
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I wonder if anyone would have any use or need any parts from that NP231 transfer case,I also have the shifter. Wonder if it would be worth listing in classifieds? Or just pitch it? Heck I would trade it for a set of fan blades for my motor.clutch is ok I think,just need blades..lol
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Unread 12-28-2011, 10:24 PM   #4
only in a jeep cj
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Nothing a little glue and duct tape can't fix.....I'm guessing the YJ was in a wreck where the front left axle broke loose from the spring and pushed the front driveshaft back a little too far?
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1975 CJ-6 304 T15 Dana20 30/44 3.73
1983 CJ-8 258 T5 300 30/44 3.31 Looking for full or half hardtop buy or trade
1986 CJ-7 Laredo 4.6 stroker T5 300 30/44 3.31
1986 TJ-7 Trail Jeep project in the works
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Unread 12-28-2011, 10:29 PM   #5
BriansCJ
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If your willing to ship(i'll pay), I'd take the planatary gear set from the 231
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Unread 12-28-2011, 10:31 PM   #6
ymurf
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Quote:
Originally Posted by only in a jeep cj View Post
Nothing a little glue and duct tape can't fix.....I'm guessing the YJ was in a wreck where the front left axle broke loose from the spring and pushed the front driveshaft back a little too far?
You are exactly right.They hit the ditch on driver side and broke leaf springs then had a slow roll over.
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Unread 12-29-2011, 08:05 AM   #7
frankush
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Looking forward to this. The sticky has gotten so long that it can be a pain to follow.
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Unread 12-29-2011, 01:57 PM   #8
dan-cj7
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I'll be watching your progress. I'm doing the same swap into my CJ.
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Unread 12-29-2011, 04:40 PM   #9
ymurf
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Well taking a break for some dinner.I got the motor and everything out..I took the whole motor mount off the frame on passenger side cause couldn't get starter to go past.Wasn't enough room. Went ahead and took the motor mounts off the 258 and put them on the 4.0.Everything lined right up on them.Only thing I will add is to use the bolts out of the 258 to mount the mounts to the 4.0.The ones on the 4.0 bottomed out,They are to long. I did take a tape measure and measured from the center motor mount bolt hole to the transmission mount.Looks like the 4.0 and AX-15 are about 5-6 inches longer than the 258 and Dana 20 that came out of the CJ7.Have to modify something for that but that's for a later post when I get to it.While I got everything out of my way I am going to go ahead and swap steering box and tilt column I got from the YJ into my CJ7. Ill let you know how that goes.


My son Taking the motor mounts off the 258.
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Unread 12-29-2011, 07:54 PM   #10
ymurf
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Well I got steering box and column out. Boxes look the same but have to use the brackets from the CJ.They haven't been off since new and two bolts wouldn't come loose.Had to use a cut off wheel to cut them off. Well the box from the YJ has metric bolts and some are to long cause CJ bracket is allot thinner than the YJ bracket I had to take off.So done for tonight.I will get bolts in the morning.Going to make another thread to see if anyone knows how to wire column up.Allot more wires on the YJ tilt column I am putting in.
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Unread 12-29-2011, 09:24 PM   #11
levergun
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Do you still have the stock cj mount? The stamped sheetmetal one? I would not recommend using it at all. It is very weak. I have seen several cracked. I'm running a agr mount on mine and it is vastly superior in strength and ridgity. Also m.o.r.e. makes a nice one. Did this swap in one a while back. Came out nice. Can't wait to see how yours comes out. Also on your slave did you decide how your doing it yet? I would greatly recommend not using the plastic master/slave assembly.
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Unread 12-29-2011, 09:33 PM   #12
ymurf
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Quote:
Originally Posted by levergun View Post
Do you still have the stock cj mount? The stamped sheetmetal one? I would not recommend using it at all. It is very weak. I have seen several cracked. I'm running a agr mount on mine and it is vastly superior in strength and ridgity. Also m.o.r.e. makes a nice one. Did this swap in one a while back. Came out nice. Can't wait to see how yours comes out. Also on your slave did you decide how your doing it yet? I would greatly recommend not using the plastic master/slave assembly.
Yea,I assume its the factory CJ mounts.Dont look very strong. My AX-15 I have does have the internal slave..Are you talking about not using the the part that mounts to the firewall or the part in the transmission? New to this so please enlighten me.What are my options?
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Unread 12-30-2011, 06:57 AM   #13
levergun
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I thought you had the external slave. For the internal you can run a early yj master. I ran a ax15 internal slave for 3 years. Went through 4 or 5 slaves. They would just start leaking. One lasted a year one lasted a month. I'm now running a external. What I was talking about is that the master/ slave for the external slave is sold as a one piece preassembled master/line/slave. I really didn't like that idea so I modified a different slave to work. The plastic assembly has issues.
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Unread 12-30-2011, 05:07 PM   #14
ymurf
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Well hasnt been a very productive day so far.Ran into problems with switching over to the 94 YJ petals. while I got the steering column out I figured I swap the petals for my power brakes and hydraulic clutch.First I noticed the brake light switch is different.For that I just used my CJ switch.If fit fine so should work. But now I ran into a bigger problem. My YJ tub is a late 80s and all my stuff I am switching to is out of a 94 YJ. I didnt know somewhere along the line Jeep changed the Hydraulic clutch master cylinder location and made the hole spread 1" wider. Needless to say petals wont fit till I try to redrill my holes for the clutch master cylinder. Guess I will try to make a cardboard pattern from the petals and transfer and drill them in my tub. Anyone here that has drilled for hydraulic clutch and knows a better way please let me know.

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Unread 12-30-2011, 09:56 PM   #15
ymurf
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I finally got the petals and brake booster and hydraulic clutch mounted..If I had to give any tips for this I would say make sure you get petals and hydraulic master cylinder from a late 80s jeep.I had to move my hole in the tub out about 1/4" and the hole spread was an inch longer on the 94 clutch master cylinder.late 80s would have been a direct bolt up.And now I had to move it out so much it hit my bulk head where the wiring harness comes through so I am going to have to move that opening a little to.Game plan for tomorrow is bolt tilt steering column in and set new motor and transmission in. here are a couple pics of the brake booster and hydraulic clutch master cylinder in.

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