Comanche 87 to 97

[Knkn90]

Turns out that the aw4 transmission is longer than the Peugeot BA10/5 transmission so the cross-member for the transmission support goes some inches back.

Good thing that the holes for the bolts in the new location are already there, you just have to tap the holes with a 10MM 1.5 taper.

I also use the cross-member and transmission support from the cherokee.

More pics for this build on Twitter @knkn9

 

[Knkn90]

 

[Knkn90]

And the transfer case in, I use the same speed sensor that I removed from the 97 2WD AW4, the only problem was that as the transfer case is now further back, the connector is not long enough, I'll have to cut the wires and add about 10" so that the connector reach the speed sensor.

 

[Catch22]

Seems we are doing the same thing and are close to the same place (although you got there much faster)

My question to you is fuel tank. Have you put any thought to it? I have read a few things but no one really documented it very well.

 

[Knkn90]

Not yet, but when I get there I'll be very detailed, I'm now working on a snapped off bolt in my rear yoke, after that I will work on the fuel lines and then the fuel pump wiring, hope to get there next week, I been updating more pictures on my twitter account @knkn9

 

[Knkn90]

 

[Knkn90]

Even With Different transmission (Peugeot to AW4) the driveshaft fit perfectly, the only issue was a snapped off bolt.

After failing trying to remove the snapped off bolt, I try changing the yoke of the Cherokee Chrysler 8.25 to the comanche dana 35 only to realize that they are different.

 

[Knkn90]

Dana 35 left, Chrysler 8.25 right

Dana 35 up, Chrysler 8.25 down

 

[Catch22]

Not yet, but when I get there I'll be very detailed, I'm now working on a snapped off bolt in my rear yoke, after that I will work on the fuel lines and then the fuel pump wiring, hope to get there next week, I been updating more pictures on my twitter account @knkn9

As for your yoke issue, there is this if you don't want to pull a junkyard factory replacement.
http://www.ironrockoffroad.com/10463.html

 

[Knkn90]

By now I will get a used yoke at my local junkyard ($10.95) and later I will swap a Ford 8.8 Diff with LSD & disk brakes

 

[Catch22]

aaaaannnnndd this is where this project typically dies.

 

[shelbyluvv]

I have a TJ tank and gauge cluster in my 97 MJ

The process is documented very well on CC under "Project Onyx"

It has been running for 6 years without a problem

 

[Catch22]

I have a TJ tank and gauge cluster in my 97 MJ

The process is documented very well on CC under "Project Onyx"

It has been running for 6 years without a problem

We fabricated some angle bracket hangers (tacked in for no just to get it driving) and its holding extremely well. If clearances work out we might keep it as is but I'm all for finding a better way.
I had actually already read your write up awhile back when we started this. We were just hoping someone found a drop in replacement or with minor work for the stock location.

 

[shelbyluvv]

Your other option that seems to be working well is a late 90s Dakota tank.

 

[Catch22]

Your other option that seems to be working well is a late 90s Dakota tank.

We would have tired this, had every junk yard not drilled a hole in them.
I never understood this practice.

 

[woowoo]

Kinda late for a solution. But that same thing happens to me. A snapped off bolt head.

I went and got a Ford u joint strap from pep boys. Drilled the snapped off bolt out and the other good one so the strap can slip through. And boom fixed.

Wish I had seen this sooner to save you time

 

[831_xj]

Yeah those work well although it sucks turning the nut like 1/8-1/4 turns. Just be careful not to torque too tight or you can crush the caps

 

[Knkn90]

I'm still working on the fuel pump and apparently I found a simple way to install the new fuel pump assembly into the old tank, I will post the info as soon as the engine start

I found this link very hard to find information:

http://www.jeep4.0performance.4mg.com/tech_specs.html

 

[cody4359]

Your other option that seems to be working well is a late 90s Dakota tank.

I have a 97-98? Dakota tank in mine. gauge reads accurate and I got a bit bigger tank. downside is it sits a little below the unibody rails, so eventually id like a skid plate for it

 

[Knkn90]

This was my first attempt at trying to use a 49psi fuel pressure regulator inside the original Comanche fuel tank

In theory should work but this pump assembly does not fit on the MJ Fuel tank
@knkn9