97 TJ w/4.0L auto to manual tranny swap??? & OT Update on me! - Off-Road Forums & Discussion Groups
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post #1 of (permalink) Old 07-06-2010, 09:56 PM Thread Starter
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97 TJ w/4.0L auto to manual tranny swap??? & OT Update on me!

Hi all, I know I've been away for awhile, so here's a quick update we're up to 3 boys a St. Bernard and a Bloodhound, and no Jeeps, had to finally bite the bullet and blow mine out after being off work for 4 months...it was either sell the Jeep and pay the mortgage or don't pay the mortgage and live in the Jeep. But otherwise all is as good as can be expected by me.

So on to my question...a buddy of mine has acquired a 97 TJ 4.0L but with the 3 speed auto, for the purpose of a little better gas mileage he wants a 5-speed manual, I know that the transmission should be readily available, but what else do I need to replace (i.e. Wiring, transfercase etc. anything you can think of) what else do I all need to do to accomplish this swap? Any suggestions in this undertaking are greatly appreciated.
Thanks in advance,
John

Please send check or money order for my bigger engine, drivetrain, axle, and tire foundation directly to me
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post #2 of (permalink) Old 07-07-2010, 04:33 PM
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This will probably be a case of spending a dollar to save a dime. He won't recover his cost for the swap anytime soon and should only do this swap if he wants a manual instead of an auto not because he wants to save money on gas. Even if he goes from 14 mpg to 18 mpg, with gas at $2.90/gallon, it will take 20,000 miles to save $900. A swap will probably be close to that much.

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post #3 of (permalink) Old 07-07-2010, 06:14 PM
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I really do not know anything about TJs so take my response for what it's worth...

Do you know if the TJ has a electronic controlled transmission? If so, then you may need a manual computer or a reflash to remove the transmission controls.

Other than that the normal stuff like a bell housing, clutch, pedals, flywheel, maybe transfer case adapter, and maybe lengthened/shortened driveshafts.

-- mike
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post #4 of (permalink) Old 07-07-2010, 08:29 PM
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Quote:
Originally Posted by WILL View Post
This will probably be a case of spending a dollar to save a dime.
^What he said.^

In the mid-70s Arab oil embargo/crisis, people were taking a beating trading new Cadillacs for Volkswagens. No way they were ever going to save enough on gas for the loss they took.

If he has a lock-up torque converter, he won’t save much anyway.

There are 10 kinds of people in the world.
Those who understand binary and those who don't.
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post #5 of (permalink) Old 07-07-2010, 09:11 PM
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He'll need the trans, pedals, master/ clutch cylinders/ hose drive shafts, I think t-cases will work, t-case linkage, manual trans computer/ wiring bits for back up lights/ nuteral safety switch, manual trans center councle if he wants it to look right. $900 would be cheap for the swap. Used AX15's are not cheap at all.

To do the swap to "factory grade" would be a pain. That being said my TJ got a solid 10 mpg with the auto and the autos do not like being exposed to water in the least bit. If he doesn't owe the bank his first born for the jeep he'd be better off selling the auto/ maybe steeling any decent parts off it and buying a 5 speed jeep.

Also is it just a street jeep or a jeep that sees the woods, if it sees the woods the following would apply.

If I was going to go through the hassel of getting rid of the auto I'd swap in something besides a factory AX15/ nv3500/ the factory 6 speed. I'm in the process of putting an sm465 in a CJ that had a T15 and it's a nightmear, an ax15 should be a little easier but not much. Something Like an NV4500 would be an ideal swap if he wheels the thing but it would be like DDing a 3-4 speed.

If he really wants over drive an AW 4 auto out of an XJ might be cheaper than dealing with a manual swap, they are really decent trans with over drives. Most of the jeep speed guys can't kill their stockers.
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post #6 of (permalink) Old 07-08-2010, 09:18 PM Thread Starter
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It is a stock Jeep, and other than the very rare logging trail to get to a hunting stand it won't even get too close to a dirt shoulder. He tows his motorcycle with it on a trailer and he's thinking he may increase his mileage when towing. I agree and have told him the savings in fuel will never pay for the swap. But it's his Jeep...I told him he'd probably be best to find one completely wrecked take what he needs and part out the rest

Please send check or money order for my bigger engine, drivetrain, axle, and tire foundation directly to me
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