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AW4 Compatibility
- Thread starter Tom R.
- Start date
4xBob
NAXJA Forum User
- Location
- Prince George, BC, Canada
Up to 1990 used a 21 spline output to the transfer case, 1991 and later use a 23 spline output. You also need to match gear cut style (early or late) within the 23 spline years. From the Novak Adapters tech pages for the 231:
"Because of differences in the cut of the gear, as a general rule; one should not interchange pre-'95 gears with post-'94 gears. These years are not hard and fast delineations. If one is not absolutely certain, disassembly and inspection is required."
Other considerations: (1) electrical connectors changed from 1990 to 1991, and again somewhere in the mid-90s. Fix is to take the tranny harness off the old tranny and put it on the new one (requires removing the pan, but not difficult) if the replacement doesn't match the vehicle harness. (2) Speedo connection and tailshaft: switched from mechanical to electronic some time mid 90s, also output tailcone got shorter.
From all of this, I think a 1991 through 1994 AW4 should be a swap without issues for your 1993 XJ.
"Because of differences in the cut of the gear, as a general rule; one should not interchange pre-'95 gears with post-'94 gears. These years are not hard and fast delineations. If one is not absolutely certain, disassembly and inspection is required."
Other considerations: (1) electrical connectors changed from 1990 to 1991, and again somewhere in the mid-90s. Fix is to take the tranny harness off the old tranny and put it on the new one (requires removing the pan, but not difficult) if the replacement doesn't match the vehicle harness. (2) Speedo connection and tailshaft: switched from mechanical to electronic some time mid 90s, also output tailcone got shorter.
From all of this, I think a 1991 through 1994 AW4 should be a swap without issues for your 1993 XJ.
