Manual Transmission Swap Questions

[G-Wag]

I currently have a stock 88 wagoneear and am in the process of swapping in axles from a j20 with 3.73's, a Dana 300 and will be running 33's or 35's depending on how much trimming is required with the 4" bds lift. I prefer a manual transmission so while it's all apart anyway I may as well swap the trans too. I'm leaning towards one of the manuals from behind an I6. The AX15, NV3550 or the 6-speed. All the posts I've read say you need to have the 4.0's flywheel balanced to match the 360's. Would I need to take a 360 flywheel to the shop or is there a spec they can match it to? It has also been mentioned that a spacer MAY be needed between the trans and the transfer case but I haven't seen it confirmed or denied. All input is greatly appreciated!

[grimgaunt]

I had to take both flywheels to the shop to balance the new one.

Yes, at least for jeep NP2xx transfer cases you need to have a 1/2 " spacer at minimum between the trans and the t-case (in my experience with a 219 and a 208)

[G-Wag]

Since I'm going from auto to manual would they be able to use the flexplate to balance the new flywheel to or do I need to source a 360 flywheel? Can I use the pedal assembly from the donor rig (XJ,YJ, or TJ) or do I need an FSJ pedal set?

[Carnuck]

They can use the 360 flexplate and balance the 6 cyl flywheel to match. You will need to use the 6 cyl starter too unless they are both the same style (solenoid coil on the starter).

[grimgaunt]

Find a FSJ pedal set from a manual tranny Cherokee or a J-truck and you will be set.

[jaber]

They can use the 360 flexplate and balance the 6 cyl flywheel to match. You will need to use the 6 cyl starter too unless they are both the same style (solenoid coil on the starter).

His '88 will already have the XJ starter.

[ThisGuyUKnow]

I had to take both flywheels to the shop to balance the new one.

Yes, at least for jeep NP2xx transfer cases you need to have a 1/2 " spacer at minimum between the trans and the t-case (in my experience with a 219 and a 208)

I have been planning on doing this swap for a while and I am like 89.9999 percent sure that no spacer would be needed for a NV3550 to run Np2xx from an fsj as it has a deeper tail housing than the ax15.... I mocked up a 3550 to a 208 and everything seemed to fit together

ax15 definitely needs the spacer.

[ThisGuyUKnow]

Find a FSJ pedal set from a manual tranny Cherokee or a J-truck and you will be set.

I am planning on doing this same swap and what I am going to try to do is you yj pedals and a yj hydraulic clutch setup by swapping the Yj pedals onto the fsj pedal assembly. I have already test fit the parts in my garage and it looks like with some metal trimmed of the yj pedals at the top everything will fit and funtion correctly on an fsj assembly.

[Carnuck]

His '88 will already have the XJ starter.

That was for anyone else contemplating this swap. Also, the spacer has to be 1" for the AX-15 or AW4 to FSJ cases 208,219,228,229 or AMC Eagle 119,128 or 129. I got mine from http://partsmike.com and they are about $100 but the studs were only grade 5 so I updated.

[Carnuck]

I compared XJ pedals to FSJ and they don't come out right (middle of the brake booster)

[ThisGuyUKnow]

I compared XJ pedals to FSJ and they don't come out right (middle of the brake booster)

If you want to run the hydraulic clutch you have to ditch the brake booster any how. The FSJ booster will impact the clutch master cylinder. I was probably going to go with a hydra set up . I have also contemplated a 95 yj dual diaphragm booster but i am not sure if that would have enough punch to stop an FSJ so I am leaning more towards the Hydra.

[Kris]

You dont need to ditch the vacuum booster to fit the clutch master.
I made a spacer for mine and had a longer rod installed in the booster.



k.

[ThisGuyUKnow]

You dont need to ditch the vacuum booster to fit the clutch master.
I made a spacer for mine and had a longer rod installed in the booster.



k.

Any specs on that spacer? I am glad you put your two cents in Kris when I have a convo with a shop or someone that tells me an ax15 or nv3550 cant hold up behind a 360 I always tell them about how your rig has held up for quite some time with one. Did you use stock FSJ clutch pedals modified to work with the clutch master? Did you use a master from a yj or something else?

[Tripwire]

dosnt the crank also need to have the hole for the pilot bushing?

[Kris]

Any specs on that spacer? I am glad you put your two cents in Kris when I have a convo with a shop or someone that tells me an ax15 or nv3550 cant hold up behind a 360 I always tell them about how your rig has held up for quite some time with one. Did you use stock FSJ clutch pedals modified to work with the clutch master? Did you use a master from a yj or something else?

You have reminded me again that I need to permalink the 2-3 threads Ive put all the specs of my swap into down in my sig or something.

Gimme a few and Ill link them.

dosnt the crank also need to have the hole for the pilot bushing?

It does.




k.