I inherited a 2WD KJ. Good thing is it's paid off and runs very well decent mileage and all, body is in great shape. However I am interested in converting over to 4x4 and I have only found a couple threads that really touch on the subject and only 1 with some pictures.

I am pretty good with a wrench and from my research this looks like a bolt in procedure no fabrication no crazy equipment needed as far as I've seen a few floor jacks and a buddy should be able to pull it off within a weekend.

I don't know what it is that I need to gather before beginning. Here is the list of items so far:

-Transfer case NP242 - which is the best transfer case to look for? Models and years? Easiest bolt up
-Transfer case lever/selector with linkage
-Front Diff/axles
-Front drive shaft
-Rear shortened 4x4 drive shaft

Am I missing anything? What about electronics? Are there any sensors that need to be wired up? Does the transfer case need a computer or control module?

Also what is a reasonable budget for all of these things? Like I said the car is paid off and I don't want to trade my KJ in because dealerships won't give me what it's worth and I'd like selling it to be a last option the car has been in my family since it rolled off the assembly line and I know it's been meticulously maintained I hate to trade that piece of mind on a possible lemon.

best thing to do is find one thats been rolled/wrecked etc and buy the whole thing, that way you have everything you need right there, all parts/ computer /wiring etc
Then scrap out the rest, interior etc, may help pay for part of the swap

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MUDD'S MOTORSPORT'S We do IFS lift installs ,
03 OVERLAND EDITION /Kilby-Skidrow-Mopar-4XGuard skids/ 2.5 inch TOTAL CONTROL JBA coilovers -JBA Arms/MOABS-31 FALKEN WILDPEAK AT3W / 4.10's etc, 04 Kilimanjaro Edition loaded, plus 05 KJ limited

Unfortunately here in Miami most KJs are 2WD at least from my own observations. Finding a wrecked one is not going to be an easy task. I thought about it and that would make everything much easier but for the sake of documenting what is needed I'd like to see if any one out there has a more complete list and specific recommendations about what is needed.


Edit: Are there any reliable online sources for the necessary parts? Does anyone have a resource for exploded diagrams and such?

What Tom said is you best and most logical option. Buy a rolled one and ship it if needed. There should be plenty, even Tampa and Jax markets should have some. Otherwise you will spend all your time researching parts, buying individual parts. Why not have a donor side by side with your KJ. And PLEASE stop calling your KJ a car. It is a Jeep, a rig, a KJ, just one of my pet peeves. sorry. Shop manual, LOSTJEEPS.com and JEEPKJ.com are excellent resources. Use all 3.

Honestly, you should consider selling the 2wd yourself and getting a 4X4 KJ. Save yourself a lot of trouble, headaches. Besides, when you are all done, you will still have a unlifted stock 4WD Liberty.

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2002 KJ 4X4, 3.7, 5 speed, offroad pkg, loaded, Moabs and Hankook A/Ts, Kenwood/ Alpine sound. Tommudd 3.5" econo lift and JBA A arms

first question - do you really need 4x4?

go check out Long_Tall_Texan - he's 2x and he's got a lift - running 265/75/16

add a limited slip/locker on the rear and you can run a lot of trails/fire roads in 2x

(the best conversion is to sell the 2x and buy a 4x4)

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

Only exception to what the others said, is if you want to go outside the box and do a solid front axle setup. At that point you're changing out a lot of stuff anyways. Also, with your list of parts in the first post, you listed a NP242. I wouldn't bother with it. NP241 would be my choice over the 242. If you're going hardcore with a SFA setup though, you'd likely look at Atlas t-cases