I have a 4.2 jeep with the AX15, a while back I got a used AX15 trans from a 4.0 jeep, the bellhousing's are the same, my t-case bolted up no problem. the problems I am having is:
1. the t-case shifter assembly, the 2 top bolts at the shifter mount, and the front t-case bolt line up, but there is a stand off with a hole and threads that block it from mounting all the way against the t-case mount. also the bolt by the pivot point is a bit larger, so, would it be save to grind away at the shifter arm mounting plate? dont look like it's near anything that's critical, and I guess I could drill the hole bigger for the lower mount. or, can I got with a 4.0 style t-case shift assembly?

2. the output shaft's pilot bearing is larger on the 4.0 trans. the only options I can think of is getting a larger ID pilot bearing with the same OD as my 4.2's crank pilot bearing hole, or can the output shaft be swapped with out much hassle?.

has anyone else done this swap? is there anything else I should be expecting to run into? I didnt really do any measurements on the output shaft splines, guess next time I am working on it I'll slide my fiber plate on to see if it is the same.



thank's for any and all help

Scott.

I did a simliar swap a few years ago and cant remember what mine came out of but for the pilot bearing I just bought the larger one that I needed and it worked fine. Cant help with the linkage though I dont remember what I did. I had other problems with it being clocked wrong and was so low it was hitting my skid plate. I had alot of t-cases laying around to use until I could get the setup I wanted.

check out AA P/N 716164 or 716166
It should be the
1.818 (Large outermost pilot hole in the crank)
X
.750 (Pilot tip on input of later model AX-15)
Confirm these numbers on your 4.2L & Ax-15