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AW-4 Transmission Swap
'00 XJ AW-4 into '97 TJ
By Tim Doumit


Stu's comments:  A number of months ago, Tim Doumit, a very good Jeepin' buddy that I've had the pleasure of sharing many Moab trails with over the years, decided it was time to come over to the dark side and put an auto tranny in his TJ.  The following is his thoughts and ideas on how he did it.  As Tim mentions, it is not a complete write-up for doing the AW-4 swap.  (we already have a couple of those on the site)  Tim's write-ups covers those things that differ, to some degree or another, from what is covered in my AW-4 write-up.  He also did a pretty good job of making a parts list the parts he used and the cost (something that is missing from mine).  A big thanks goes out to Tim for sharing this information with all of the site's readers.  It will certainly be useful for anyone else that is contemplating an AW-4 transplant into their TJ.  With that being said, here is Tim's write-up.



This write-up should be used in conjunction with Stu Olson's AW-4 Swap. He and some other fellows went before me and worked out most of the kinks. There are a few things that I did differently that some may find interesting and helpful to say the least. I know that I would have not attempted this swap without the information provided in Stus pages.


This swap is not for the feint of heart.
 

First of all I started off with a list of parts I thought I needed. After looking over the other AW-4 write-ups, I was ready to start accumulating everything possible. The prices I am about to list are current as of the summer and fall of 2008.

The actual swap took me 22 days. Working mostly on my own with a recently repaired right arm, I think I did pretty well.

One of the least expensive things I purchased for the swap was the transmission itself. I found it at a wrecking yard with only 20k on it.
$225.00

The dealership helped with much of the new parts I wanted to get.

Drive plate
Spacer
Dust covers
Bolts for the crank and torque converter
Dowel pins
$170.00

Other assorted parts from bone yards across the nation:
XJ pedal assembly (stick with TJ) and TCU $50.00 Light Truck Parts Portland OR.
TJ auto shifter bezel $32.00 Davies Jeeps. Salem OH.
XJ tub plate, shifter with bezel and cables. $50.00 EBay
XJ tub plate TCM plug and lighting harness $20.00 D&S Salvage. Longview WA
XJ odds and ends like dip stick tube and shift cable bracket $25.00 Ace auto wrecking. Longview WA.

Summit got me for a bunch too:
BMM-70265 transmission cooler $55.00
EAR-982268ERL -6 AN to � NPT 90 adapter (x2) $15.00
SUM-220701 Twist-tite -6 AN straight (x2) $4.00
SUM-220706 Twist-tite -6 AN 45 degree (x2) $10.00
SUM-220711 Twist-tite -6 AN 90 degree (x2) $10.00
SUM-220785 Twist-tite -6 AN hose 20� $50.00
RUS-670150 Adapter -6 AN to � (x2) $9.00
RUS-648070 -6 AN to 14mm o-ring (x2) $11.00 (make sure you get the o-rings off your old stock tube adapters or buy new ones shown on Stu�s write-up.)
ATM-2260 weld in adapter for gauge $13.00
ATM-4357 Autometer gauge $47.00
BMM-70298 Hi-Tek cooling unit $200.00

Tom Wood's custom drive shaft:
The rear was shortened - $65.00
New front shaft - $260.00

Wire, heat shrink, moldex plugs, and other assorted bits probably came in around $150.00

There were other things that I purchased for the swap that I decided not to use or did not need. So, summit will get the things not listed back. The pro-tube I purchased will get used for something else. The moldex plugs for the most part were cut out of my harness because I just did not like them. Two remain near the transmission since I could not locate the OEM plugs for that area.

 

Onward

Before I started the swap I gave myself plenty of time to find out all I could first and I did that with the help of the Jeeps Unlimited.com TJ Forum. Here I was able to get responses, comments and advice from those who went first. There is seven months of opinions, tips and answers there.


Let's skip ahead to the first thing I did, the wiring harness:


As you can see this wiring harness is multi-colored. This was something I needed to do to keep things straight. I was fortunate enough to get all the wires right the first time. With Stu's wiring pages and the color schematic I made everything went real smooth.

One thing I should have done is measure it correctly as there is too much wire under the dash. I was going to cut and re-solder but I will wait and do that when I am able to purchase an AWSHIFTER. On a side note, my wiring was color coded like Stu's swap. Just to be sure, I used a FSM for the 97 TJ and another form a 00 XJ.

 

Clocking for the t-case:
 

mrblaine loaned me his AW-4 clocking jig. He even tossed in a reamer and drill bit of the correct size. It makes the procedure virtually impossible to screw up.

 

With the TeraLow 4:1 I needed to shorten the input shaft on the transfer case. One of many times I followed the leader.  Angle grinder + cutting disc = perfect length.

 

More AW-4 Tranny Swap

 

 

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