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Modified Tech Discussion Forum for Tech related discussion for Modified XJ's and MJ's.

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  #1  
Old April 6th, 2021, 10:20
Da XJ nut's Avatar
Da XJ nut Da XJ nut is offline
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Some real FUN about to be had XJ with ZJ parts


I have a 97 XJ 4 door 2wd at the moment and I was given a rolled over 97 ZJ 4x4. both 4.0 auto trans. The XJ is AW4 and the ZJ is 42RE i know with the NP242. Question is....can I use the transfer case adapter from the 42RE on a AW4 so I can put my 242 under my XJ and am going to use the axles from the ZJ also since they're already built up with 3.73 gears, lockers, and upgraded shafts. don't know who did it but I'm grateful. I have lots of experience building, fabricating and have full shop/tools and welders at my disposal. Going to weld spring perches to the tops of the D35 rear axle and going to lift it 4.5- 5 inches to clear 33's may have to trim fenders but not scared. Any advice out there about output shaft swap vs. cutting it off to length for conversion.

Thanks everyone who read this
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  #2  
Old April 6th, 2021, 10:53
RCP Phx RCP Phx is offline
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Re: Some real FUN about to be had XJ with ZJ parts

The answer is no to almost everything you asked about doing. There is no interchangeability between the AW4 and the 42rle. You will also need to rebuild the AW4 to install the correct tailshaft.
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  #3  
Old April 6th, 2021, 12:40
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Da XJ nut Da XJ nut is offline
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Re: Some real FUN about to be had XJ with ZJ parts

I just need to replace the output shaft, trans has only 20k on it and shifts great. I use the vehicle as a daily driver at the moment. I know I can use the 242 transfer case and axles because I have both driveshafts from the ZJ also.
I had read in an earlier post that someone said you could cut down the shaft instead of swapping it. I did mention that both were 97's and both outputs are 23 spline. Thanks for the input
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  #4  
Old April 6th, 2021, 12:59
RCP Phx RCP Phx is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Quote:
Originally Posted by Da XJ nut View Post
I just need to replace the output shaft, trans has only 20k on it and shifts great. I use the vehicle as a daily driver at the moment. I know I can use the 242 transfer case and axles because I have both driveshafts from the ZJ also.
I had read in an earlier post that someone said you could cut down the shaft instead of swapping it. I did mention that both were 97's and both outputs are 23 spline. Thanks for the input
You must have mis-read, mis-interpeted something.
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  #5  
Old April 6th, 2021, 13:33
bajabronco bajabronco is offline
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Re: Some real FUN about to be had XJ with ZJ parts

I have both a XJ and a ZJ. The TCase out of the ZJ will bolt right up to the XJ and vise versa. I put the 231 out of my 2000XJ into my ZJ temporarily while I rebuild the 242 that it had. The only thing to check is that the output length is the same, it should be since all 96-98 ZJ's have .840" 23 spline input
All 96-01 XJ's: .840" 23 spline inputs.
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  #6  
Old April 6th, 2021, 15:38
Unclewolverine Unclewolverine is offline
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Re: Some real FUN about to be had XJ with ZJ parts

What he is asking about is if he can use the zj 4x4 adapter on a 2wd aw4 to mount the transfer case, which from what I remember is a no, not even a aw4 adapter will help. Maybe halmca will see this, he just converted one and had every problem in the book.
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  #7  
Old April 6th, 2021, 19:51
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Re: Some real FUN about to be had XJ with ZJ parts

Im just going to buy a 4x4 AW4 from a local salvage yard and build it with my trans internals
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  #8  
Old April 6th, 2021, 19:53
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Re: Some real FUN about to be had XJ with ZJ parts

I'm just going to buy a 4x4 AW4 from j/y this weekend and build it with my internals
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  #9  
Old April 7th, 2021, 05:34
Unclewolverine Unclewolverine is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Make sure you get the right one! Read the aw4 swap guide to make sure.
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  #10  
Old April 7th, 2021, 06:48
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Re: Some real FUN about to be had XJ with ZJ parts

Getting it out of a 96 XJ with the 231 transfer case. Going to use the 242 still because I'm not using the vacuum lock front axle. I can source both for under $175.00 but will most likely have to use just the output/ tail shaft from that trans to put in mine after removing tail housing and using the extension housing that I don't yet have. They should be compatible with each other from what I've read. I should have never sold my last XJ build....
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  #11  
Old April 7th, 2021, 07:01
RCP Phx RCP Phx is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Just so you realize, you have to dis-assemble the entire trans to install the tail-shaft. It's easy but I definitely wouldn't call it fun.
https://naxja.org/forum/showthread.php?t=1159116
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  #12  
Old April 7th, 2021, 07:09
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Re: Some real FUN about to be had XJ with ZJ parts

I'm a Trade Instructor, I teach a class on Maintenance & Light Repair. I just have never converted from 2wd to 4wd and didn't realize the XJ and ZJ were that much different or I wouldn't have gutted the rolled ZJ down to the dash. I took engine, trans w/ transfer case, fuel tank all lines from front to rear, Master cylinder, axles, seats front and rear with carpet console shifter plate all brackets, rods ect. I really thought I could've found a ZJ 2wd cheap to build it and leave my XJ alone to just enjoy driving it. I'm experienced in trans building, I built the one in my XJ now. 20k on it so far no issues. The best part is I have students that can help me with this fun and they're learning to love Jeeps too !
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  #13  
Old April 7th, 2021, 09:57
RCP Phx RCP Phx is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Sounds like you have it made and free labor to boot!!!
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  #14  
Old April 7th, 2021, 10:22
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Da XJ nut Da XJ nut is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Thank you for your guided advice, I have been checking out your build and trans stuff...very impressive. I do love the free labor and the ability to use my shop and equipment whenever I want. I also take care of my hard workers, they helped me swap a 4.6 to a 5.4 in a 97 f150 4x4 and got it running last year so I threw them a pizza party for the hard work. But my XJ is going to be soo much more than that. I love the rear bumper mods you did. never saw the finished pics of it, have you finished it ?
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  #15  
Old April 7th, 2021, 12:13
RCP Phx RCP Phx is offline
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Re: Some real FUN about to be had XJ with ZJ parts

Sure did........ https://naxja.org/forum/showthread.php?t=1160514
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