Jeep 4.0L swap

BigBody79

BigBody79

Well-Known Member
Joined
Mar 30, 2005
Location
Lumberton
I am getting ready to do a 4.0L swap on the jeep and have a few questions regarding the t/c and transmission.

the jeep had the 2.5L/Ax-5 drive train the new 4.0L has a aw4 behind it. I am not getting the transfer case with this 4.0L and the aw-4. Will the np231 switch between the ax-5 and the aw-4
 
It depends on the year. AX5's have a 21 spline output. Early AW4's (pre 4.0) also had 21 spline. If you are swapping in a 4.0 (1991 and later) then the AW4 has 23 spline output. Make sure you get the AW4 brains. It's a fully electronically controlled tranny.
 
Kevin is correcton the early aw4's 90 and older are 21 spline, what year 2.5 and what year 4.0 ? there are a few guys around here who have done the swap, myself included, the hardest part is the wiring. there are other options for shifting the aw4 if you do not get the complete wiring harness www.AWshifting.com
 
I am really concerned about spending my money on doing this swap. Does anybody have any good advice that would help me with the decsion. I know the the motor that I am getting comes with the computer and all things that it needs to run and well as the transmission. I know that I am going to need to change the t-case imput shaft.

Mainly my concerns lay in other things such as other wiring. Under dash wiring. Acessories. Things like that. Anything else that I have forgotten or issues that I should ponder before spending my money.

The main question is this swap worth it? It is either this or rebuild the ax-5.
 
The swap is really not that hard. You will tie in the 4.0 bulk connector to the stock 2.5 bulk connector on the firewall. It will not affect any of your accessories. Don't waste you time with the POS ax-5. Again, what year 4.0 and what year 2.5?
I have bulkhead pinouts for a 89 and 92 2.5 and 89 4.0. I would be more than willing to send you coppies of this stuff if it would help you out any. Also I can e-mail you lots of other 4.0 swap info. Check out http://www.cjoffroad.com/forums/default.asp there is alot of good info there
some more links
http://www.off-road.com/jeep/tech/4lswap/index.html
http://www.chrr.ohio-state.edu/~bogrees/html/tech/40swap.html
 
I can give you anything and everything you would need to know on the 2.5 yj wiring. As for the 91 4.0 all the stuff I have is the old renix wiring stuff. pre 91. I actually think doing you swap will be easier than what I did, I had to convert from OBD-1 to renix. you will be going obd-1 to obd-1
 
Alright a little update
I have the engine pulled out of both jeeps. the 4.0L motor is from a 90 jeep well at least that is what the computer has. The transmission is from a 94 ZJ and the jeep that this is all going in is a 92 wrangler.
some things that I have noticed are the distribution box right beside the battery list completely different things is completely different places. I thought about just swapping one for hte other but the 92 has things such as abs and some other things that i thought would be a good idea to keep these things. the trans also has two electrical plugs on them that i have no idea where they go. I don't see any provisions on either harness for them.

any helpful info is much appreciated.
 
if its a 90, its a renix controlled motor. The 2 plugs on the tranny are for the TCM (tranny computer) I will sit down later tonight and type out the wires you will need to splice at the PDC for this thing to fire up and run
 
Might wanna check your tranny. I think the 94 ZJ had the 42RE in it not the AW4. The AW4 went in the early ZJ's from 93. They switched to the 42RE in mid 93. The 42RE is electronically controlled in the higher gears and will also have a TCM. It might even make for an easier swap. Here's an AW4. http://www.novak-adapt.com/knowledge/aw4.htm
 
ok sorry for the crappy picture, I free hand drew it to explain the bulkhead connector, the connector between the yj and xj is the same just the wires are in differnt terminals
730353_42_full.jpg


the top part of the bulkhead connector terminals 123 on the yj are all lighting, you will not need to mess with them

1992 YJ
A1 BL/RD PARKING LAMPS
A2 VT/OR REAR WASHER PUMP
A3 BR/RD RIGHT TURN
A4 NOT USED
A5 NOT USED
A6 NOT USED
A7 GY/BK BRAKE WARNING SWITCH
B1 BR/WT DAYTIME RUNNING LAMPS
B2 WT/BK DAYTIME RUNNING LAMPS
B3 NOT USED
B4 WT/OR SPEED SIGNAL
B5 BK GROUND
B6 GY/BK BRAKE BULB CHECK
C1 WT/OR SPEED SENSOR
C2 GY/BK LEFT TURN
C3 NOT USED
C4 GN/OR EMMISIION MAINT. INDICATOR GROUND
C5 GN/RD CHECK ENGINE IDICATOR GROUND
C6 WT/BK BACKUP LAMP SWITCH/ AC RELAY
D1 LG/BK FOG LAMP
D2 NOT USED
D4 PK/WT HAZZARD FEED
D5 WT/YL IGNITION START AND RUN
E1 WT/RD HI BEAMS
E2 LB/BK HI BEAMS
E4 RD/OR HEADLAMP SWITCH FEED
E5 NOT USED
F1 NOT USED
F2 NOT USED
F3 VT/WT WINSHIELD WASHER PUMP
F4 NOT USED
F5 NOT USED
F6 BR UPSHIFT SWITCH
G1 NOT USED
G2 NOT USED
G3 GY/OR HORN
G4 RD/YL FUSE BLOCK FEED
G5 GN STARTER RELAY/CRANK
G6 GY/OR HORN REALY
H1 LG LO BEAM
H2 NOT USED
H3 NOT USED
H4 PK IOD BATTERY FEED
H5 LB/YL STOPLAMP SWITCH
H6 OR TACH SIGNAL

1989 XJ 4.0 (SHOULD BE THE SAME AS YOUR 1990, SINCE THEY ARE BOTH RENIX)

A1 GY/BLK LEFT TURN
A2 BK/LB UPSHIFT INDICATOR
A3 LG/BK WINSHIELD WIPER
A4 LG/YL ANTI-LOCK PUMP FEED
A5 NOT USED
A6 RD/WT BATTERY DRAIN DISSCONECT
A7 NOT USED
B1 DB PARKING LAMP FEED, LIGHT ON BUZZER
B2 VT/WT WINSHEILD WASHER PUMP FEED
B3 DB/WT WINSHEILD WIPER HIGH SPEED
B4 NOT USED
B5 BK/YL FULL TIME INDICATOR LAMP
B6 YL IGNITION SWITCH 1-1
C1 BK/RD PART TIME INDICATOR LAMP
C2 YL/BK BACKUP LAMP FEED
C3 GN/WT TACHOMETER
C4 PK/BK FUEL PUMP FEED
C5 BR/WT REVERSE SWITCH
C6 LB OIL PRESSURE INDICATOR
D1 RD BATTERY
D2 VT COOLANT TEMP
D4 RD BATTERY
D5 LG DIMMER SWITCH LO BEAM
E1 ACCESSORY POWER
E2 GY HORN RELAY
E4 WT DIMMER SWITCH HIGH BEAM
E5 OR/BL BLOWER MOTOR FEED
F1 NOT USED
F2 BR RIGHT TURN
F3 BK BRAKE INDICATOR W/O ABS
F4 BR ACCESORY IGNITION EXPORT
F5 GY/RD BRAKE INDICATOR
F6 VT/WT WASHER FLUID LEVEL SWITCH FEED
G1 LG/BK FOG LAMP SWITCH
G2 TN/GN BATTERY INDICATOR LAMP
G3 WT/BK WINSHEILD WIPER LO FEED
G4 BK INSTRUMENT PANEL GROUND
G5 TN/BK A/C REQUEST
G6 OR 1-3 IGNITION EXPORT
H1 LG A/C THERMOSTAT SWITCH
H2 DG IGNITION SWITCH START
H3 TN/BK WINSHEILD WIPER/ PARK FEED
H4 LG/BK A/C MODE SELECTOR SWITCH
H5 VT/OR REAR WIPER WASH SWITCH
H6 WT/OR LOW WASHER INDICATOR


NOTES, G4 ON WRANGLER, THE FEED WILL NEED TO COME FROM THE GAUGE CLUSTER POWER WIRE

FUEL PUMP FEED ON THE WRANGLER DOES NOT TIE INTO THE PDC, YOU WILL HAVE TO SUPPLY AN IGNITION SWITCH POWER SOURCE TO THE RELAY IN THE XJ WIRING

As you can see there are lots of wire from the xj that will not be used, the only xj wires used are the engine related wires, none of the lighting or winsheild washer wires will need to be used, they can all be stripped out of the harness

Let me know if you need anything else. I have the FSM for the 92 wrangler and 89 XJ both, that is where both of these pinouts came from

YOU CAN BUY ME SOME :beer: FOR THIS LATER :flipoff2:
 
Also doing a swap from 2.5 to 4.0 in a 2000 wrangler

Kinda wondering, I have a guy selling a (4.0)motor and(5spd) (2wd) tranny out of a 98 cherokee. Was wondering if anyone had info on if the tranny will work, engine wiring harness, computer and if i need anything else to do the swap? Any info will be greatly appreciated
 
I have a 89 YJ that had a 2.5L in it with a AX 5. i got a 4.0L and AX 15 with a 231 transfer case from a 91 XJ cherokee. I have the interior wiring harness from the YJ still in my YJ and i have the engine wiring harness and computer ECU from the XJ. i am trying to wire it up but need help. do you have a bulk head connector diagram for the 89 2.5 YJ and one for a 91 4.0L XJ or close to that. thank you
 
keep us posted on the progress.
 
bad news... I just see my wrangler is a 1991 model. the connector doesn't coresponding. erfff
:mad:
on the yj, i have 13 connections and on the xj, 17 connections :/
I will try to do something with the color wire on the list.
Later, I will post pics :)
 
Back
Top