Topic: Aw4 transmission into a TJ??

[stan98tj]

Has anyone done it here? Is it a ridiculous task? Can it be done? I saw a thread from Stu Off road where he had swapped on in.
The reason I'd like to do it is that HPA is going to base the TDi diesel swap for automatics on the AW4. They like the fact it has an overdrive and consider it to be an upgrade from the 3spd auto (which I have). SO, I want to know what's involved and how complicated is it. Stu's seemed pretty in-depth, but he was going from manual to auto. How bad of a swap do you guys think this may be?

[sharpxmen]

can you drive standard? i'd go with NV3550 over any auto to be honest.

i think oldjeep put one in his YJ (which is now gone but he had a swap thread on jeepforum or some other jeep site, can't remember).

[Jeffy]

Chuck/oldjeep put one in his YJ.  Thought most AW4's are for the 4.0L and use that bolt pattern.  Earlier ones were available with the 2.5L though.

[stan98tj]

I don't think I would have to worry about the bolt pattern as HPA is setting up the package for the diesel to be set up with the AW4. So, on the motor end, it will work. I'm concerned about mounting the trany to the vehicle, fitting the Atlas and retaining my high clearance skid. I think they will want me to use a 98 or later AW4

[oldjeep]

It isn't a bad swap at all, and you get more clearance with an AW4 than with a manual.  Once you use an auto offroad you'll never go back to rowing gears.

You're going to want to set up some sort of manual shifting for the diesel though unless you have a way of altering the shift points in the AW4 TCU.

Few pictures here:
http://4bangerjp.com/forums/index.php/topic,2614.0.html

[stan98tj]

It isn't a bad swap at all, and you get more clearance with an AW4 than with a manual.  Once you use an auto offroad you'll never go back to rowing gears.

You're going to want to set up some sort of manual shifting for the diesel though unless you have a way of altering the shift points in the AW4 TCU.

Few pictures here:
http://4bangerjp.com/forums/index.php/topic,2614.0.html

I totally get the standard transmission purists, but off road I prefer an auto. From
What I gather, you clocked it and adapted it to the motor, that part I feel will be taken care of with the swap kit I'm getting from HPA. What I'd like to know is how your skid mounted.

[oldjeep]

I totally get the standard transmission purists, but off road I prefer an auto. From
What I gather, you clocked it and adapted it to the motor, that part I feel will be taken care of with the swap kit I'm getting from HPA. What I'd like to know is how your skid mounted.

I clocked the tcase by redrilling the tcase adapter.  The transmission was held up by a 1.5" square crossmember - solid mounted to the trans and bushed at the frame.  The skid plate was a separate flat piece of steel that bolted to the bottom of the frame rails using the stock skid plate bolt holes.

[stan98tj]

I clocked the tcase by redrilling the tcase adapter.  The transmission was held up by a 1.5" square crossmember - solid mounted to the trans and bushed at the frame.  The skid plate was a separate flat piece of steel that bolted to the bottom of the frame rails using the stock skid plate bolt holes.

So you have a "flat belly skid" or tummy tuck? But it had to be custom made? Wonder if I could re-use the UCF one I just bought. If not, guess I can sell it :(
I went looking for overall lengths to see if I can actually fit everything I want. Overall length of the AW4 is 25"3/8 and the Ax15 is 24". I tried looking to find the overall length for my 30rh but didn't find anything. Now comes the transfer case. I want to run a 4speed Atlas, which I understand is a hair shorter than a 231 with an SYE. Some searches I did turned up guys having to use super short SYE or Mega Short ones as the rear shaft was pretty short. Not sure if that is possible with an Atlas, but one of the guys had an Atlas 2spd+doubler box so perhaps that is why he needed a Super Short SYE.

[dwtaylorpdx]

Your going to be needing enough custom work, that moving the power plant forward 2 or 3" shouldn't be a big stretch. Since its an auto use a cable style shifter and there wont be any issues there..

UNless your doing a 4.0 there engine bay has plenty of room.. :)

Dave

[Jeffy]

I don't think I would have to worry about the bolt pattern as HPA is setting up the package for the diesel to be set up with the AW4. So, on the motor end, it will work. I'm concerned about mounting the trany to the vehicle, fitting the Atlas and retaining my high clearance skid. I think they will want me to use a 98 or later AW4

You're going to want to ask HPA which bolt pattern they are using.  The two are different and you don't want to be working on one from a 2.5L when you actually need one from a 4.0L.  I doubt HPA is making a new bellhousing but rather an adapter plate so you need to get the pattern right.  I suspect they're going with a 5.0L since it's more common BUT they could easily use the AX5 adapter on a AW5 with the same pattern...  The AW4 in the 2.5L only ran from 1987-1990 while the 4.0L ran from 1987-2001.

[stan98tj]

You're going to want to ask HPA which bolt pattern they are using.  The two are different and you don't want to be working on one from a 2.5L when you actually need one from a 4.0L.  I doubt HPA is making a new bellhousing but rather an adapter plate so you need to get the pattern right.  I suspect they're going with a 5.0L since it's more common BUT they could easily use the AX5 adapter on a AW5 with the same pattern...  The AW4 in the 2.5L only ran from 1987-1990 while the 4.0L ran from 1987-2001.

I think they want the 98 or later AW4 because of the sensors and stuff.

[oldjeep]

So you have a "flat belly skid" or tummy tuck? But it had to be custom made? Wonder if I could re-use the UCF one I just bought. If not, guess I can sell it :(
I went looking for overall lengths to see if I can actually fit everything I want. Overall length of the AW4 is 25"3/8 and the Ax15 is 24". I tried looking to find the overall length for my 30rh but didn't find anything. Now comes the transfer case. I want to run a 4speed Atlas, which I understand is a hair shorter than a 231 with an SYE. Some searches I did turned up guys having to use super short SYE or Mega Short ones as the rear shaft was pretty short. Not sure if that is possible with an Atlas, but one of the guys had an Atlas 2spd+doubler box so perhaps that is why he needed a Super Short SYE.

The skid was custom made - just a flat piece of 5/16 plate that I cut.  I've got a 30rh from my daughters TJ sitting on the bench - could measure it if you like.

My motor was moved forward 7", which also raised it since I just cut off the motor mounts and slid them up on the frame rails.   Since you are considering a diesel, then this is all academic since that will fit differently than either a 2.5 or 4.0 regardless of your trans choice.

FWIW - the 2.5L AW4 was 87 and 88 only, there is no way they would be using that as a base.  The bellhousing was different and it used fewer clutches and steels than the 4.0L version.