AW4 swap

[RAT]

Curtis,
is your T case shifter still stock or aftermarket? If it's still attached to the body throw that POS away and get a direct acting.

[curtis]

Kurt I have one of the frist ones Skyjacker put out. One of the plastic sleeves was missing so I replaced it with a brass bushing. Also I redrilled a couple of holes so it lines up better. Seems to work good now, but time will tell.
Will also wait on doing the flat belly skid till after I see how the gearing works out with the swap. Will also probably change the rear upper front CA mounts with the stretch when I do it.

[Jeeperator]

The TC looked ok on the inside. The fork has a little wear and I tried to ajusted it some. The plan now is see how the gearing is with the new trans. Might be time for 5 to 1 or 4 speed.

Going from a manual to an aw4 auto your 1st gear ratio will be not as low but the torque converter effectively doubles your crawl ratio. Ideal for extreme crawling is 100:1 you definatly will be over that. With a 5:1 tc you better upgrade too some big brakes because with that crawl ratio in low I bet they wont stop you.

[aw12345]

Busy man there eh Curtis, that is going to be a very nice Jeep when you are done with it.
Guess the plan is to do this stuff without popping a wheely

[curtis]

That's a great shot Art. Some day soon. Got the exhaust done today. And just need to put the console in and brake pedal. The great thing about this swap is it only takes 4 wires to make it work. 3 to the shifter and 1 to the TC.

[curtis]

Some pictures of the progress.

pedals before



pedals out of jeep



pedals fixed and installed




console installed




exhaust



Can I cut the wires going to the airbag switch in the console ?

[inVERt'D]

Can I cut the wires going to the airbag switch in the console ?

If you haven't already, disconnect the battery. Be careful with those things. They can kill you.

[aw12345]

Pull the fuses for them behind the glovebox and cut or remove what ever you like. I ditched all that stuff in mine

[Jeeperator]

Any updates Curtis? Been out of the loop for a while. I was going to start mine as soon as it cools off.

[curtis]

Beau I had a pin hole in my trans cooler. So they sent me a replacement and I got it in yesterday.

This plug was attached to the 5 sp trans and I though it was just for the backup light. But it also has to do with the starting. So I had to run 3 wires from the PCM to the gray plug on the new trans to make it start.



So now I think I need to run a wire from the gray plug to the harness at the trans for the back up light.

Beau where the shift cable goes through the firewall. There is a rubber plug that I took out and cut a 1 1/4 in the center for the gromet on the shift cable. The hole in the firewall is to big for the gromet on the cable.

[Roundeyes]

I definitely like the swap you are doing!
I have an 04 TJ with a 5sp. (Like you did). I’m going to start looking for all the parts to do the same swap you are doing please keep the pictures coming and any info you can thanks.

[Jeeperator]

Yea that plug must be tied into the clutch switch which will only allow your jeep to start when the clutch is pushed in. Since you have no clutch now it wont start until you tie the wires into it with the neutral safety switch on the trans. Didnt think it was 3 wires for starting though. I know 2 wires on the nss complete a circuit for starting when in park or neutral and one wire can be used for the reverse light since the old switch was in the 5 speed trans. Make sure you dont over fill the trans even a little bit. Those aw4 trans dont like it one bit. Experience with my toyota 4 runner while towing a while ago.

[curtis]

I'm not using the TCM. So I used the fused ignition switch output(st-run),park/netural position switch, and a ground out of the PCM to the gray plug. I may do away with the park/netural switch wire later so I can start it in any gear.
Put the cooler back in ( took almost 8.5 qts ). Trans works in all gears. Really going to like shifting it manually, takes me back to the old drag racing days. Going to put the front DS back in and take it out to the riverbed in the next couple of days and see how it does.

[curtis]

Got the DS back in today, so it's off to the riverbed in the morning for a test run. Then back to the house and check for loose bolts and leaks. If all is good then up to angelus oaks the back way and back down the 38 to home. Then JB or Holcomb on tuesday or wednesday. I sent my DS to tomwoods and they retubed (bent) lengthened it, replaced C.V. socket yoke,boot and balance. and gave me a strap and bolt kit for the front yoke and shipped. 65.00 bucks. You can't beat them for service.

[curtis]

Well every thing worked great today and no problems. I might mess with the TV cable and clutch packs later. The stall speed will take a little time getting used to. With a clutch you have instance throttle response.
But you can shift it with the stock shifter From 1st to 3rd to 4th. You just need to wind it out in 1st and it will shift. Or just use the Baja shifter for 2nd gear. The baja shifter keeps the trans from searching for gears which is real nice.
The TC lock will work good for the crawl ratio,but might need some help with the brakes. LOL