A little bit of background; This is a 1991 Grand Wagoneer (we call it the Waggy) that we bought off of Craigslist. It was destined to become target practice, so we rescued it. We've been poking along, doing repairs and maintenance as needed to get it up to trustworthy condition. This swap is the first major thing we have done to it.
Notes pertinent to this manual trans swap:
1. We swapped out the NP-229 transfer-case because it almost left us stranded. We now have an NP-208. I'll leave the NP-208 swap info out of this write-up, others have covered that elsewhere. If y?all are just itching for another write up on that part, let me know.
2. We installed hydroboost brakes along with the manual trans. That has also been well covered elsewhere, but if you see something different about ours, or just want to hear more about it, feel free to ask.
3. We have a 1? body lift which does provide just a little extra space between the floor and the top of the transmission.
4. We're slackers, this write-up was completed approximately 1 year after the swap was completed. We did manage to make notes for the write-up starting the day after we finished the work, so you can see our original plans and we've added notes in the post so you can also see what we've already learned didn't work.
In standard Jeep modification fashion, we chose to replace the automatic since there was absolutely nothing wrong with it! I have a general distrust for automatics, they always feel broken to me, I just can't seem to get used to the slip of the torque converter. That being said, it was a great automatic! (I hope no-one reads that last sentence)
In case you just want to know what parts we used, I'll start with the parts list, and approximate prices on this stuff. Prices are different everywhere, so please know these are just a guide, your results may vary...
Parts - Junkyard
~ $160
From a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans. It has unknown mileage, but shifted smooth in the junkyard and the XJ was wrecked, so at least we know someone was driving it!
AX-15 transmission
bellhousing
shifter
flywheel
reverse light switch
clutch master cyl
clutch slave cyl
~ $0 ? Already had it from other projects
From a 1989 Jeep Cherokee XJ, Renix injected 4.0, 6 cyl Peugeot 5 speed trans.
front driveshaft
From a 1991 Waggy
crossmember
rear driveshaft
part of automatic trans shift linkage
~ $35
From a ~ '93 YJ
steel transmission mount ? has four bolts connecting it to the bottom of the trans, and two bolts connect it to a rubber isolator that bolts to a crossmember
~ $5
Late '80s Ford Ranger, 2wd, manual trans
shift boot (square-shaped for best fit)
~ $20
From an early '80's Jeep J-10, manual trans
clutch pedal
clutch pedal pivot rod
~$253
From a Chevy Astro van
Hydroboost ? ordered from Elliott on IFSJA.org
Parts ? Shiny new ones!
~ $140
Novak Adapters
Clocking ring, part #153 ? intended to clock Dana 300 behind AX-15, NV-3550, etc... (in this case, we used it as a spacer)
~ $130
For a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans.
clutch
pressure plate
throwout bearing
~ $50
For a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans.
Stainless steel clutch hydro hose & adapters from http://www.jdaent.com/oemreclli.html
~ $5
For a 1973 Jeep CJ-5, 304 V8
pilot bushing
For a 1984 Jeep J-10, 6 cyl automatic trans
front emergency brake cable ~ $37.50
intermediate emergency brake cable ~ $14.50
~ $12
For a early '90's Jeep Cherokee XJ
shift knob
~ $110
For a 1991 Grand Wagoneer
Poly drivetrain mount kit from BJs
Machine work
flywheel resurface ~ $30
flywheel re-balance ~ $75
Parts ? Fabricated
transmission torque arm mount
Notes pertinent to this manual trans swap:
1. We swapped out the NP-229 transfer-case because it almost left us stranded. We now have an NP-208. I'll leave the NP-208 swap info out of this write-up, others have covered that elsewhere. If y?all are just itching for another write up on that part, let me know.
2. We installed hydroboost brakes along with the manual trans. That has also been well covered elsewhere, but if you see something different about ours, or just want to hear more about it, feel free to ask.
3. We have a 1? body lift which does provide just a little extra space between the floor and the top of the transmission.
4. We're slackers, this write-up was completed approximately 1 year after the swap was completed. We did manage to make notes for the write-up starting the day after we finished the work, so you can see our original plans and we've added notes in the post so you can also see what we've already learned didn't work.
In standard Jeep modification fashion, we chose to replace the automatic since there was absolutely nothing wrong with it! I have a general distrust for automatics, they always feel broken to me, I just can't seem to get used to the slip of the torque converter. That being said, it was a great automatic! (I hope no-one reads that last sentence)
In case you just want to know what parts we used, I'll start with the parts list, and approximate prices on this stuff. Prices are different everywhere, so please know these are just a guide, your results may vary...
Parts - Junkyard
~ $160
From a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans. It has unknown mileage, but shifted smooth in the junkyard and the XJ was wrecked, so at least we know someone was driving it!
AX-15 transmission
bellhousing
shifter
flywheel
reverse light switch
clutch master cyl
clutch slave cyl
~ $0 ? Already had it from other projects
From a 1989 Jeep Cherokee XJ, Renix injected 4.0, 6 cyl Peugeot 5 speed trans.
front driveshaft
From a 1991 Waggy
crossmember
rear driveshaft
part of automatic trans shift linkage
~ $35
From a ~ '93 YJ
steel transmission mount ? has four bolts connecting it to the bottom of the trans, and two bolts connect it to a rubber isolator that bolts to a crossmember
~ $5
Late '80s Ford Ranger, 2wd, manual trans
shift boot (square-shaped for best fit)
~ $20
From an early '80's Jeep J-10, manual trans
clutch pedal
clutch pedal pivot rod
~$253
From a Chevy Astro van
Hydroboost ? ordered from Elliott on IFSJA.org
Parts ? Shiny new ones!
~ $140
Novak Adapters
Clocking ring, part #153 ? intended to clock Dana 300 behind AX-15, NV-3550, etc... (in this case, we used it as a spacer)
~ $130
For a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans.
clutch
pressure plate
throwout bearing
~ $50
For a 1998 Jeep Cherokee XJ, 4.0, 6 cyl, manual trans.
Stainless steel clutch hydro hose & adapters from http://www.jdaent.com/oemreclli.html
~ $5
For a 1973 Jeep CJ-5, 304 V8
pilot bushing
For a 1984 Jeep J-10, 6 cyl automatic trans
front emergency brake cable ~ $37.50
intermediate emergency brake cable ~ $14.50
~ $12
For a early '90's Jeep Cherokee XJ
shift knob
~ $110
For a 1991 Grand Wagoneer
Poly drivetrain mount kit from BJs
Machine work
flywheel resurface ~ $30
flywheel re-balance ~ $75
Parts ? Fabricated
transmission torque arm mount
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