4x4 Conversion with Pictures

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

Well, here I am, 1/2 way through my 4x4 conversion on my 2003 KJ 3.7L with the 45RFE. As of now, I am almost done installing the T-case. I am currently working on mounting the linkage. Today I got my 2WD 45RFE converted to a 4WD 45RFE and got the NP242 mounted up. So the only difference in the 45RFE between the 2WD and 4WD models is that the 4WD model has an adapter plate for the transfer case whereas the 2WD model has a tail extension. Output shaft length and spline count are the exact same. Also, the interior center console can remain and the floorboard already has the space cut for the 4WD shifter. I will probably finish up the front end tomorrow or Saturday as work permits. A more detailed report and more pics to come!

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

Well all done with the transfer case portion! Now on to the front axle! Just have to get the bushing for the transfer case linkage!

fortx4 KJ · **Posted:** Thu Jul 04, 2013 3:13 am

Cool project your tackling there. Can't wait to see it finished.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

The POS Dana 30a is in!

Dje Ryu · **Posted:** Sat Jul 06, 2013 8:58 pm

Wow, that's a lot of work to just use the stock front diff.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

Yeah, however, 18 year old on a budget here. The axle took just under one hour to install. Hardest part was loosening the LCA's to install the mounting through-bolts. The stock diff will be fine so long as tires are not spinning, and I have always been careful about that. JBA's was far to expensive, because if mine does blow up, another one can be had for $200, and installed in less than 3 hours time.

TheJawsOfDeath · **Joined:** Sun Nov 05, 2006 3:56 am **Posts:** 305

Props to you for tackling this project! Looks like you have all the pieces in order and know how to make it run. Maybe my memory fails me but I think this is the first 4x4 conversion I have ever seen.

audiboy86 · **Posted:** Sun Jul 07, 2013 11:52 am

Dropping that front differential is a SOB for sure I would hate to have to drop the whole engine cradle also. The transmission transfer case is also a pain without a good transmission jack.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

audiboy86 wrote:

Dropping that front differential is a SOB for sure I would hate to have to drop the whole engine cradle also. The transmission transfer case is also a pain without a good transmission jack.

Used a regular floor jack and my chest for the transfer case portion lol. Also, unlike popular belief, you do not have to touch the cradle at all to get the diff in. You have to remove the LCA's but that is it, it rotates forward and slides out without issue. I installed it in less than one hour.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

never actually posted a pic of my little blue mule. Here she is as she stands a few months ago. OME 927/948 Bilstein HD front, 5100 extended rear. JBA 4.5's

audiboy86 · **Posted:** Sun Jul 07, 2013 1:24 pm

Oh I know you don't have to drop the front cradle to get the front diff out but isn't that a front cradle in the floor of your garage?

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

yes it is, came with the parts when I bought them from a guy that parted out his KJ. He sent the entire front end.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

All done! Finished a few days ago, but have not had time to post up! Works awesome! No issues thus far! :BINGO:

VIDEO OF THE FINISHED PRODUCT!

http://www.youtube.com/watch?v=9SGmFz5n ... e=youtu.be

candpliberty · **Posted:** Fri Jul 12, 2013 3:15 pm

EXCELLENT! :BANANA:

JeepCoMj · **Joined:** Fri Feb 22, 2013 11:54 pm **Posts:** 161

nice.

I've done this twice now, but was replacing the engines as well so I simply lifted the body off the suspension, k-member, trans, motor and all with the harness laid on the motor, and set it back on the "new" parts after I rebuilt the motors.

very easy, bolt-in, nothing to complain about.

tommudd · **Posted:** Fri Jul 12, 2013 10:35 pm

jacob03kj wrote:

Yeah, however, 18 year old on a budget here. The axle took just under one hour to install. Hardest part was loosening the LCA's to install the mounting through-bolts. The stock diff will be fine so long as tires are not spinning, and I have always been careful about that. JBA's was far to expensive, because if mine does blow up, another one can be had for $200, and installed in less than 3 hours time.

Couple of shortcuts that allows you to R&R the front diff and never touch the LCAs , can R&R in less than an hour.

jacob03kj · **Joined:** Mon Apr 18, 2011 10:47 pm **Posts:** 34

tommudd, care to share that secret? Would be much appreciated.

TwoBobsKJ · **Joined:** Fri May 11, 2012 8:03 pm **Posts:** 463

Congrats!

Great to see a young man willing and able to jump in and make this work - now your "blue mule" will REALLY show it's stuff :JEEPIN:

Bob

0uTkAsT · **Posted:** Sun Jul 14, 2013 5:53 pm

Very nice

Awesome job man

4x4 Conversion with Pictures

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