Prepping for the big drivetrain swap

[Nightpath]

Howdy all,

I'm preparing for my big drivetrain swap, but before I order a bunch of parts I just need to make sure that I have the essentials.

I am swapping the current 258 and old drivetrain out for a newer low km 4.0L / AW4/ NP231 from my donor Jeep. This is the list of parts that I have to order to complete it that I know of :

- Fuel pump - in tank for an XJ  (current one on XJ has a broken tube)
- Engine mounts - Jeep CJ I heard fits good
- Oil pressure switch
- Oil pan gasket for 4.0L - (probably go with cork)


Here is my plan :

I plan on keeping the 4.0L as stock as possible, this means the fan system as well and A/C pump. I may look for an electric fan (Ford Lincoln?). I can always move the battery tray or cut it and weld in a box for the battery. I *may* swap to the ZJ waterpump/fan combo if there is absolutely no way to fit the stock XJ parts in, but I'm trying to stay on a budget and buying a new waterpump, fan and belts really isn't in it right now.

Using the XJ crossmember, will have to be lowered and slid back a tad. This will be fab work. Then there's the miscellaneous prep work, like grinding down the rib on the block, and cutting the power steering pump bracket. XJ fuel pump. Slide that sucker in, most of the lines are new metal ones so it should be good to go. My mechanic buddy is a brake/fuel line specialist so it's no worry.

With the AW4+231, does the front driveshaft have to be lengthened? Can I use the XJ front or rear driveshaft on the Eagle?

Swapping over the 258 oil pan to the 242. Besides replacing the gasket is there anything else I should purchase for this?

I want to swap the Eagle steering box out for the one from my XJ, as well as the power steering pump. Is this doable?

Also swapping my defunct rear axle out for a Dana 35 with 3.55 (and swapping the shock mounts around), and swapping my front axle out for a SX/4 Dana 30 with 3.55. The bearings appear to be good in the D30 I picked up, but the seal for the driveshaft is leaky...will any Dana 30 seal fit this?

Along with this, I'll be snagging some other things that need attention. Ujoints, a few other gaskets and seals, etc.

Is there anything missing from my list? I'll update is as I go along, try to keep it pertinent for anyone wanting to do this swap as well. When I actually start it I'll be taking photos.

[eaglefreek]

I'll answer the ones that I know. I had the Eagle front drive shaft made longer and used a 2wd Grand Cherokee rear shaft and had it shortened. You can have the 4x4 XJ one made longer, but it costs more to make it longer. Steering box is a bolt in.

[Nightpath]

I'll have to measure my Eagle driveshaft.  I know the one on my old xj is a hair above 30 inches.

[eaglefreek]

I'll have to measure my Eagle driveshaft.  I know the one on my old xj is a hair above 30 inches.

If you're talking about the rear, the Eagle shaft has a slip built into it where as the NP242 has a slip yoke requiring a solid shaft. If you were to install a SYE(slip yoke eliminator) you might be able to use the Eagle shaft without modification.

[Nightpath]

My XJ has the 231, looks quite similar to the Eagle's driveshaft.

[eaglefreek]

Does the your 231 transfer case have fixed rear yoke or slip yoke? If fixed, at some point a SYE was installed.

[Nightpath]

Not there atm...trying to remember from looking underneath. How can I tell?

[carnuck]

If the shaft slips into the tcase instead of bolting on (with a slip joint in the middle of the shaft) then it's a stock XJ/whichever 231

[carnuck]

Top two are fixed yoke and the bottom one is slip yoke (TJ style) Earlier ones slide into the trans like a car driveshaft.

http://www.novak-adapt.com/images/pics/transfer_case_parts/231_driveshaft_angle_comparison.jpg

[Nightpath]

I'll have to check that out when I get back to it but I think it looks like the sye.

Besides what I mentioned above to purchase, is there anything else I should be considering?

[Nightpath]

OK...what do I need to look for in regards to fitment?

I know that the rib needs to be ground off, and the power steering bracket needs a bit of modifying.

What is this I hear about an intake not clearing the brake booster?

[carnuck]

Pre '98 HO intake will hit the booster. Renix will just barely clear.

[Nightpath]

I take it that I'll have to bang a good old dent in it for it to clear will I?

[Nightpath]

Should I look for a intake from a later XJ, or just tap a dent into mine so it'll clear?

[eaglefreek]

I could have sworn I saw at least two Eagles posted here with 91-98 style intakes and they cleared the booster.  I wouldn't be putting a dent in a brake booster.