Has ANYONE converted a pre-ODBII ZJ to AW4? - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 05-05-2007, 12:45 PM   #1 (permalink)
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Question Has ANYONE converted a pre-ODBII ZJ to AW4?

My 95 ZJ is limping on it's 42RE and I REALLY want to hasta that bitch and get an AW4 in there! I've found a bunch of info on AW4 conversions, but can't seem to find any good sources on how to do this with my configuration. I'm aware of the AW Shifting option, but I'm hoping to keep full auto working, as it's my DD (daily driver) and is also often used to haul my drunk ass from some bar to the nest of myriad DD's (designated dames). I'm not afraid of the solder gun. Just need to know where to put what. Much appreciation in advance....
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Old 05-05-2007, 01:03 PM   #2 (permalink)
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I stuck one in a YJ. The AW4 has a separate TCU, so it doesn't really matter what kind of computer the engine has.
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Old 05-05-2007, 02:15 PM   #3 (permalink)
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thanks oldjeep,

Did you use the TCU from a pre-ODBII vehicle? I'm hearing that 96 up had the TCU combined in the ECU.
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Old 05-05-2007, 02:37 PM   #4 (permalink)
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So, what motor is in the jeep you want to convert?
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Old 05-05-2007, 02:51 PM   #5 (permalink)
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thanks oldjeep,

Did you use the TCU from a pre-ODBII vehicle? I'm hearing that 96 up had the TCU combined in the ECU.
I used a TCU from an 89 on mine - had to because of the limited years for a 2.5L with AW4. You would want to use one from a 91 or newer, that way the TPS signal is easier to hook up.
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Old 05-05-2007, 03:00 PM   #6 (permalink)
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So, what motor is in the jeep you want to convert?
It's the stock (1995) 4.0L
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Old 05-05-2007, 03:06 PM   #7 (permalink)
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I used a TCU from an 89 on mine - had to because of the limited years for a 2.5L with AW4. You would want to use one from a 91 or newer, that way the TPS signal is easier to hook up.
Thanks again oldjeep, good to know that
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Old 05-05-2007, 03:46 PM   #8 (permalink)
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BTW - Why don't you just sit down and rebuild the tranny you have? You can get a complete overhaul kit for about $120 or you could get a kit with red eagle clutches and kolene steels for about $190. I think a trans rebuild would probably be much easier and less costly than swapping transmissions.
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Old 05-05-2007, 07:00 PM   #9 (permalink)
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Wow, this is hardcore.

Read n00b.

/forum/jeep-hardcore-tech/402017-hardcore-tech-forum-info.html
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Old 05-05-2007, 07:23 PM   #10 (permalink)
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BTW - Why don't you just sit down and rebuild the tranny you have? You can get a complete overhaul kit for about $120 or you could get a kit with red eagle clutches and kolene steels for about $190. I think a trans rebuild would probably be much easier and less costly than swapping transmissions.
If it were only slipping or shifting weird, rebuilding would be my first choice. This trans was professionally overhauled ($2200!) and 30K miles later started crapping out again. The overdrive section sounds like it's eating itself alive, which would surely require a number of pricey parts and excessive downtime. Add to this my lack of knowledge and experience (not having a handle on which parts are still in usable shape) and the idea completely loses it's shine for me. Plus, I've heard much good and little bad about the AW4, quite the opposite for the 42RE.

I'm hopeful that (1) I'll find a reasonable deal on a fairly young (late 90's) AW4 attached to it's original 231 and a TCU from an early 93 ZJ (the few months in history the ZJ had this superior and much more common trans!), then (2) I'll swap/add these in with the mastery of a Jedi Knight and (3) when things don't happen as hoped, I'll find quick answers here, get this done and be smiling for at least the next 100K miles!
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Old 05-05-2007, 07:28 PM   #11 (permalink)
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Old 05-05-2007, 07:29 PM   #12 (permalink)
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Am I wrong to consider a project involving wiring in a TCU (to a vehicle that didn't originally require one) hardcore tech?
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Old 05-05-2007, 08:00 PM   #13 (permalink)
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Am I wrong to consider a project involving wiring in a TCU (to a vehicle that didn't originally require one) hardcore tech?
Yep.
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Old 05-06-2007, 06:13 AM   #14 (permalink)
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Am I wrong to consider a project involving wiring in a TCU (to a vehicle that didn't originally require one) hardcore tech?
Not really, it seems that the General Chit Chat crew has followed you into a tech forum for some reason.


Find yourself an FSM for your ZJ, the factory wiring diagrams will save you a ton of headaches. When you find your AW4, if you can't get the full chassis side harness, make sure you get all of the chassis side connectors.
There's one on the TCM,
1 on the NSS,
1 that hooks to the tranny solonoids,
and possibly one hooked to a comfort power switch
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Old 05-06-2007, 08:21 PM   #15 (permalink)
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Quote:
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Plus, I've heard much good and little bad about the AW4, quite the opposite for the 42RE.
IMHO, you will find someone to bash every type of tranny that is out there. I've heard people complain about the AW4 too. I would suspect that most of the people who are complaining about the 42re haven't had one apart either. I've seen these trannys last 200k miles if taken well care of.

But I can understand the reason you're wanting to go the route that you are on due to the fact that hard parts will likely be needed. I would still suggest taking the trans apart if you have the time though because you might be surprised with how much you may be able to salvage. You may also learn something for the next trans you need to work on.
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Old 05-06-2007, 08:28 PM   #16 (permalink)
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That's great advice, I almost bought the FSM from the ebay manual guy, but thought his price for used was unreasonable. I'll check back when I have my parts and I'm ready to begin.
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Old 05-06-2007, 08:55 PM   #17 (permalink)
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yeah, mondtster, time is an issue for me. I'm pretty sure I can get this swap done in a weekend; bustin' the case, head scratchin', ordering parts, waiting for parts, etc., too much downtime! Another thing that makes me want to do this is the relatively huge number of AW4's on the market. I've been offered two of them for free, and I'm having trouble finding a used 42RE for under $600.

If you, or anyone here wants this 42RE when I'm done with the swap, I'll crate it for free, you pay only shipping.
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Old 05-07-2007, 04:53 AM   #18 (permalink)
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If you, or anyone here wants this 42RE when I'm done with the swap, I'll crate it for free, you pay only shipping.
Where are you located? I'm always kinda looking for more tranny parts...
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Old 05-07-2007, 06:53 AM   #19 (permalink)
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The 42RE is a POS but I'm not sure it's worth the effort to convert to the AW4. A friend of mine has one behind his 98 but he uses that "stick" style shifter you can buy.
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Old 05-07-2007, 07:17 AM   #20 (permalink)
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Not really
No, really. It's not hardcore. No where in the list does it mention transmissions.
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Old 05-07-2007, 06:58 PM   #21 (permalink)
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Where are you located? I'm always kinda looking for more tranny parts...
Between Sac and Tahoe. Smog is a regular part of my diet.
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Old 05-07-2007, 07:58 PM   #22 (permalink)
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That's a bit too far away from me to make it worth shipping a trans. Oh well...

Good luck with the project.
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