Dj5 4x4 conversion guide

[Montanaphilly]

So youre probably wondering how.
Well here it goes.
If you want to do the conversion the best advice i could give to you is buy a donor cj.
my mail jeep came with a AMC 232 i6 and tf 727 Transmission . To convert the transmission to 4x4 , you would need a mainshaft and tailhousing from a dodge 4x4 that came with the 727. 203 Transfer Case to go with also . The biggest problem is without doing a wheel base stretch , you will not fit an autotrans and x case in that little mail jeep . with the measurements i got, my rear drive shaft would have been 10" long. Couldnt work.
Anyhow , got my hands on a T-150 trans and Dana 20 x case. Bought a flywheel and bushing made for the 232/t150 combo. Bolts for flexplate were too short , so new bolts were need too.

Stock Crossmember needed to be repositioned farther down for x case to fit . And it just barely does. Onto the clutch. The stock cj linkage works for only a left hand drive setup. So get ready to do a hyraulic cylinder and pedal setup. They sell the amc kits. Now were at the front end. The narrow track Dana 30 CJ7 or CJ5 is a direct bolt up.( but vary in knuckle types/ brakes, You will need new u bolts and springplates. As the stock mail jeep axle tube is a larger diameter. After youve bolted on the front end now comes the steering. Youre gonna need to save the passenger side knuckle. It is a double hole knuckle and will be needed for the 4x4 axle to work with the stock steering,

Lifting may be a must as i have a 4" lift in the front and almost have clearance issues with the front drive shaft.( rear shat off of cj7)
This is just the info ive gathered , as i cannot take full credit . But i did the conversion myself and with a little time , yes it is possible.

Any questions?

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[gert]

Re: 4x4 How to:

Thanks for the info maybe we can get the moderators to pin this to the top of the page very useful to know what your up against


And yours looks pretty neat as well


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[Montanaphilly]

Re: 4x4 How to:

How do I edit this post? I need to fix the title and add more info....

 

[Montanaphilly]

Re: 4x4 How to:

I'm new to the site just cant figure out where to edit my post and title,

 

[Posi]

Re: 4x4 How to:

The general membership can not edit titles
Although members can edit their posts it has to be done within a few hours of posting.

 

[Petescj]

Re: 4x4 How to:

I'm new to the site just cant figure out where to edit my post and title,

Pm me what you'd like to change it too and I'll fix it.

 

[Montanaphilly]

Re: 4x4 How to:

Pm me what you'd like to change it too and I'll fix it.

Ok cool messaged you

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[2verpsters]

So youre probably wondering how.
Well here it goes.
If you want to do the conversion the best advice i could give to you is buy a donor cj.
my mail jeep came with a 232 and tf 727 transmission. To convert the transmission to 4x4 , you would need a mainshaft and tailhousing from a dodge 4x4 that came with the 727. 203 transfercase to go with also . The biggest problem is without doing a wheel base stretch , you will not fit an autotrans and x case in that little mail jeep . with the measurements i got, my rear drive shaft would have been 10" long. Couldnt work.
Anyhow , got my hands on a t150 trans and dana 20 x case. Bought a flywheel and bushing made for the 232/t150 combo. Bolts for flexplate were too short , so new bolts were need too.

Stock Crossmember needed to be repositioned farther down for x case to fit . And it just barely does. Onto the clutch. The stock cj linkage works for only a left hand drive setup. So get ready to do a hyraulic cylinder and pedal setup. They sell the amc kits. Now were at the front end. The narrow track dana 30 cj7 or cj5 is a direct bolt up.( but vary in knuckle types/ brakes, You will need new u bolts and springplates. As the stock mail jeep axle tube is a larger diameter. After youve bolted on the front end now comes the steering. Youre gonna need to save the passenger side knuckle. It is a double hole knuckle and will be needed for the 4x4 axle to work with the stock steering,

Lifting may be a must as i have a 4" lift in the front and almost have clearance issues with the front drive shaft.( rear shat off of cj7)
This is just the info ive gathered , as i cannot take full credit . But i did the conversion myself and with a little time , yes it is possible.

Any questions?View attachment 82351View attachment 82352View attachment 82353View attachment 82354View attachment 82355View attachment 82356

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Getting into this conversion myself. Want to do a 4" lift also. My running gear is out of a 73 Commando. AMC 258 i6 / 4.2l , T-15 . Motor and Transmission are in place. Front axle from the Commando with its power steering is in place. DJ was RHD, now will be LHD. Have both the Commando rear axle and the DJ rear axle. Would prefer to use the DJ axle since it has the correct shock mounts and spring pads. Would have to switch the gearing but I have that out of the Commando rear axle. How did you achieve the 4" lift to match the front. In the pic above you have the DJ rear axle but the springs look stock. Figured I would have to cut and remount the spring pads under the axle and go with YJ style 2.5" wide springs but the DJ is approx 43" eye to eye, YJs are at least 45" eye to eye. Any insight would be appreciated. Pete