zj build

wncmtnrunner

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i just recently bought a 94 zj 97k w/ alltime 4wheel drive Excepionaly clean. i am looking to make it a weekend wheeler/dd.I really want to do a tranny and tcase swap because i hate the alltime 4x4 but i love it for my first jeep.I had a 4runner so i am kind of new to jeeps what is the best way to build a zj for dd/weekend wheeling.
 
If you want to swap Tranny and T-case, (good idea on the '94) find an AW4/231 combo or an AW4/242 combo.

right now, you should have a 42re/249 combo. the 42re is crap as are any of the re/rh series of trannys they went to after mid '93. the 249 is good for about 80-90K miles then the Viscous Coupler (the thing that makes it AWD) goes south on you and it's $700 for a new one. Swap those two out and the rear axle and you'll be good on the drivetrain up to 33" tires.

Look for XJ's for the AW4/231 combo. there will be some computer issues, but there are work arounds for that.
 
WAIT REAR AXLE I THINK I HAVE THE CHRYSLER 8.25 and the computer issuses how do i resolve them and do you know anyone whocloud do the swap for me and what kind of lift should i do
 
I have a Rubicon Express 4.5" short arm kit on my ZJ and it does good double duty as a DD and weekend wheeler. I'm running 33x12.50x15 mt's. Another transfer case option, not as strong as a 231 though, is to look for a NP242 case from another ZJ. It will be stronger than the 249, still give you selectable AWD if you want/need it. I have a 242 in mine works fine at 140k. I considered putting a 231 in mine but by the time I built it like I wanted I could buy an Atlas II. So I'm sticking w/ the 242 until...
 
wncmtnrunner said:
WAIT REAR AXLE I THINK I HAVE THE CHRYSLER 8.25 and the computer issuses how do i resolve them and do you know anyone whocloud do the swap for me and what kind of lift should i do
Click to expand...

You sure about that? I didn't think the ZJ's came with those, but I guess someone could've swapped one in. If it did come from the factory with it, then that's the first I've heard of it. It's better than the D35 or the D44AL that came in ZJ's, but still leaves some to be desired for as heavy as the ZJ is.

Like Rox&Mud, I'm running an RE kit, but I think mine is the 3" or 3.5" whichever it is. It does fine, but I'm not impressed with the Douschtech(sp?) shocks that came with mine.


Oh and talk to zubz on this board about computer issues. He's done a few. Or I bet you could google it.
 
Not to Hijack the thread, but I have a 231 I'd love to swap into my '96 with the 5.2 and the AWD case. But, it's from a GM product. What 231's will fit behind my trans? Kinda new to the ZJ's
 
nope, but rustys springs are stiff from what i've heard...but the rustys kit is pretty cheap. if you want the cheapest lift do a front to rear spring swap and put the front springs in the rear(lift 3-4") and get a set of front 3-4" lift springs and some shocks if you want the cheapest way to do it.
 
In the early years they did actually use the Chrysler 8.25 in some
ZJ's when there was a huge shortage of terdy-fives. It's uber rare to find one though. You have the 35 most likely.
 
spykosshow said:
In the early years they did actually use the Chrysler 8.25 in some
ZJ's when there was a huge shortage of terdy-fives. It's uber rare to find one though. You have the 35 most likely.
Click to expand...

yup, kinda like the 5spd option in 93
 
DemonDave said:
Not to Hijack the thread, but I have a 231 I'd love to swap into my '96 with the 5.2 and the AWD case. But, it's from a GM product. What 231's will fit behind my trans? Kinda new to the ZJ's
Click to expand...

the GM 231 might work behind your trans, but itll most likely have the 27 spline input which will need to be swapped out for the 23 spline... also i think the shift linkage was a little different

http://www.4x4wire.com/jeep/tech/xfer/249-231/
 
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