JKU X 4wd conversion

Wish I had seen your post sooner dead feat... lol but its ok

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So I just finished installing the shifter assembly and cable.
[img width=1200 height=675]http://img.tapatalk.com/d/14/03/15/zy3udeja.jpg[/img]

This is what it had covering the stick hole... [img width=1200 height=675]http://img.tapatalk.com/d/14/03/15/e4ynemym.jpg[/img]

When I lifted the console all the studs for the 4x4 shifter linkage were there... just needed to put the nuts in and done, the cable hole where it routes thru the frame had a cap in it you can just pop out and feed the cable through.

I just secured the cable and am waiting for the drive shafts to install the tcase...
[img width=1200 height=675]http://img.tapatalk.com/d/14/03/15/ynygu5y9.jpg[/img]

Not sure how that cable is routed around the tranny there... a picture fo someone else's setup could help [img width=1200 height=675]http://img.tapatalk.com/d/14/03/15/desysuqe.jpg[/img]

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So it happens that only automatic transmission JKs need the tcase adapter... all I had to go by was other write-ups and they all said an adapter was needed with a shorter tailshaft coming out of the tranny, the manual transmission is actually longer because the housing pictured above is where the tranny shifter is at, the automatic doesn't have that so thats why they use an adapter so they can mount to the crossmember and the tcase where the manual shifting housing would be.... so that is $300 less needed for this conversion.

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So the driveshaft are here and I started working on installing the tcase then I find out that the main/output shaft is 30 splines and too short, so now I need to find either a shot tranny to part out or buy the output shaft which is about $450... I don't know how hard it would be too swap that out but I'm willing to try it. On the other hand the shaft is so short that it wouldn't even engage into the tcase input. About a 3/8 gap in between the two. So I wonder of its viable to have a short shaft made to mate the two, and is 3/8 gap enough to not compromise strength in such a shaft, it would be about 2.5" long but there is definitely some play as to the outside thickness it could be...

Well I've just decided to replace the main shaft on the transmission to the 4x4 one, treating it down and swapping the bearings and gears on it ain't difficult. Tech manuals are great! https://www.google.com/url?sa=…g2=zSwEWZIT6_BraocOVfw6WQ

Well we tore apart the transmission and swapped the shaft...

Top is the new one and bottom is old shaft

The length and splines were different of course. The whole swap went smooth except we had to cook a bearing race and a thrust washer to install it on the new shaft.

Above you can see how the splined end sticks out enough while the other setup (not pictured) was recessed by about 2 inches into the transmission.

Swapped the yoke on the rear and the front and bolted on everything else.

Only issue was tcase shifter did not go fwd enough to engage 2H so we relocated the tcase lever pin (where the shifter attaches to the tcase) to the rear of it's plate. Tl;dr cut and rewelded it.

Not sure if I should be worried about that front shaft being so far out in the splines...

So... the 4x4 conversion is done. im putting her in the sand next week on tuesday or so. And for final prices it goes $14,000 + $2690 in all the stuff done for the conversion and other items I wanted. Do math guys im sure that is way cheaper than prolly all X model JKUs out there. plus i have nice coast 1310 driveshafts and rebuilt transmission so I know thats good!

Shout out to Astape! he regeared my axles and let me help him so i could learn!