[craftsmancollab]

A few years back I finally pulled the trigger and yanked a well-loved AX15 from the local pick and pull. Lots of parts, a full rebuild and install later and the 2000 XJ build looks like it came from the factory with an AX15 / manual trans. Even the shift light now works on the gauge cluster 😎 🧰

Wanted to compile some takeaways and especially a parts list from the build.
Most all of the donor parts came from a 1998 Cherokee - and all installed into my 2000 Cherokee over a few weeks time.

Out with the old (Clapped Out AW4) in with the new (rebuilt AX15)

First test run on the new manual swapped setup - San Diego to San Luis Obispo (~300mi)

 

[craftsmancollab]

Complete XJ AX15 Swap Parts List:

Yanking the donor parts from the pick and pull meant one chance to get it right.
I pulled everything I could think of that differed from my automatic factory XJ to the manual donor.
Glad I did - as there's lots of little parts to make things work as they were designed.

Sourced From Manual Transmission Donor Cherokee:

XJ Manual Transmission: AX15 (Pref. 1994-1999)
(Complete with transmission, bellhousing, shifter assembly, hardware & reverse light switch)

XJ Transfer Case (Matching NP231/Manual Spec)

Manual Trans Front Driveshaft (Length Is different Than Automatic)

Rear Driveshaft (Rec. Aftermarket Upgrade To Double Cardan DriveShaft)

Manual Donor Crossmember & Transmission Mount

Cherokee Pedal Assembly W/ Clutch Pedal (Clutch/Brake Combined Assembly)

Clutch Assembly, Master & Slave Cylinder

Throwout Bearing & Shift Fork Assembly

Flywheel, Flywheel Hardware, Flywheel Cover, Etc.

Steering Column (May be able to modify Auto column to work)

Interior Shift Boot/Trim Fitting

Manual Transmission PCM/ECU (Needs to Match Your Vehicle’s Year & Reflash For 5-Spd)

Replacement/Service Parts:
Transmission Mount, AX15 Rebuild Kit, Proper Pilot Bearing, NP231 Rebuild Kit, Clutch Kit, Master & Slave Cylinder Kit, Ax15 Oil (10W-30), NP231 Transfer Case Fluid (ATF+4), Gaskets & Tube of Gasket Maker.
Replacement shift boot, shift knob, as needed.

Aftermarket/Upgrade Parts:
Rear Driveshaft - Double Cardan Upgrade

Slip Yoke Eliminator Install (Recommend for all lifted / 4x4 builds)

 

[Digger84]

for 2000 4.0 PCM also needs to match californium emissions (4 oxygen sensors and mini cats) or a federal emissions 2 oxygen sensors and no mini cats
but no such issue with 2001 as all are californium with mini cats (50 state emissions starting 2001)

 

[craftsmancollab]

for 2000 4.0 PCM also needs to match californium emissions (4 oxygen sensors and mini cats) or a federal emissions 2 oxygen sensors and no mini cats
but no such issue with 2001 as all are californium with mini cats (50 state emissions starting 2001)

Great point - yep.
2000 PCM requires matching: Fed or Ca Emissions, Manual or Auto Trans, 4.0L.
E-Vin & Mileage is stored in the PCM as well - which is necessary to keep accurate for smog in many states.

I'll have to see if I have still have the P/N spreadsheet for all the model year PCM options to add here.

 

[craftsmancollab]

After sourcing all the swap parts - I decided on a full garage rebuild of the AX15.
It shifted fine at the junkyard, spinning the input shaft by hand, but teardown revealed expected wear on the clutch, syncros, etc.

I have some more info on the craftsman collaborative site about the rebuild as well as the complete photo gallery of each AX15 Rebuild part/process, so I'll just put a recap here and get back to the swap.

The whole transmission can be built over a few days/week in the garage depending on experience and how detailed you get.
As a first time transmission rebuild for myself, I labeled every part, took before and after pictures to troubleshoot (note the full gallery above), and kept parts stacked in an organizing bin until it as time to reinstall.

There were a few manuals/articles and a youtube series I followed that made the step-by-step process easy to follow - I can try and pull those up and link them too.

In short, you strip the AX15 down to the gear columns, break them apart with a shop press, replace the syncros, inspect the gears, and press the assembly back together.
Check clearances with a feeler gauge all around, and continue onto reassembly. I found no gear issues/wear that stood out - so the full rebuild kit I purchased covered the majority of rebuild parts.
Once the gears, syncros and shifter assembly was buttoned up, I tested it for clearances and proper movement one last time, then bolted the cases back together and went for install on the Cherokee.

 

[craftsmancollab]

Compiled some more details on the AX15 swap and build options/details beyond the above writeup -> find that here:

AX15 Swap - Jeep XJ Auto to Manual Guide - Craftsman Collaborative

The Iconic AX15 Swap: Giving Jeeps of All Years an Upgrade Over The Factory Drivetrain. Your Complete Conversion Guide & Parts List ->

craftsmancollab.com

Any info / questions missing? - give me a holler here!

 

[ronnieh]

Hey will a 96xj pcm work in a 2000xj for an auto to manual swap? What does the pcm have to do with a manual transmission?

 

[Digger84]

No it will not
a 96 has non bus controlled gauges and a single coil with a single coil driver
a 2000 has a cluster running off digital messages on the ccd bus and three separate coil drivers for the 3 coils in the coil rail

also depending on federal or California emissions a 2000 has either 4 or 2 oxygen sensors while a 96 always has 2