Topic: Transfercase shifter YJ on XJ Transmission (AX5)

[Eucalypta]

Hej Guys,

I swapped my broken AX5 for an AX5 from a XJ.
The boltpattern on the transfercase side is somewhat turned, therefor the transfercase is turned down on the leftside.
This causes no problems (yet), however...

It is easy to put the car into 4Lo but back is a PITA. The shifter pulls the switch "over the top" of its travel and is then completely aligned with it.
So pushing the stick forward will result in pushing the shifter rod to the top of the switch.

Has anyone a sollution to this problem?

If it is unclear, I can post some pictures later on.

Thnx,

John

[sharpxmen]

pics would help.

one thing i can think of if i understand the issue correctly is to offset the position of the lever on the transfer case, you could weld a little tab at the end so it offsets the hole where the rod is and it won't be inline when in 4Lo (this is just by guessing what you meant).

[Bounty Hunter]

 The XJ transmissions clock the front output of the transfer case down lower.  You can drill 6 new holes in the tailhousing of the transmission to put the transfer case back up where it belongs.

Or try lengthening the shift rod.

[Jeffy]

Swap the old transfer case back?
Swap the front section of the old transfer case?

[sharpxmen]

Swap the old transfer case back?
Swap the front section of the old transfer case?

it's the transmission he swapped, holes are clocked towards driver side on the XJ AX5 tailhousing

[Jeffy]

Doh, that's right.  Well he could swap the rear half of the case.  Drilling a new set of holes would be easier.

[aw12345]

Swap the old transfer case back?
Swap the front section of the old transfer case?

I bet it's the transmission that has the holes clocked different.
Make a clocking ring and stick the transfercase back where it belongs, that's the right way of doing it. Or lower the transfercase shifter so the linkage lines up better.
Choice A is the better way to go, even with just mudding , ground clearance is a good thing, the less stuff dragging through the mud the better

[sharpxmen]

Doh, that's right.  Well he could swap the rear half of the case.  Drilling a new set of holes would be easier.

problem with swapping the rear 1/2 is that you might need to redo the shimming on the shafts, dunno how much is involved as i never opened the AX5 but if the only problem he has is the shifter is lot easier to fix that than taking the transmission apart.

[Bounty Hunter]

 A clicking ring would be a waste as its easier to redrill the case if there's enough material.  Done often for the aw4 swap.

[aw12345]

Clocking ring more like a drill guide to get all the holes aligned, not to sandwich in between

[Eucalypta]

Thnx guys, lot of suggestions to work with; from my poor description you all seem to have pictured it right in your mind.

Drilling new holes would be a nice solution, need to make them right on the spot and well aligned. I do not have a workshop so I'll have to see if I can find someone to help me with it.
Same goes with a clocking ring; even more machining and I do not know if my output shaft is long enough; drilling new holes seems more easy.

I didn't think of placing a tab on the mounting of the lever; if it works it is the most simple solution; I would also need to bend the shift stick to get it the right way in the cabin.

I am also going to look into the possibility to make a longer transferlink, this would be a little trial and error.

Will keep ya all posted.

[Eucalypta]

Made a small bracket which makes the shifter arm about 1" longer. Now the angle between the shifter rod and the switch is better.
It shifts great now, whithout any problems.

Thnx guys !

[sharpxmen]

nice and easy, cool solution.