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99 XJ Manual swap mounted to OM617

Old 09-25-2018, 05:16 PM
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Default 99 XJ Manual swap mounted to OM617

I posted this over on Cherokee forum and didn't get any responses. I figure this forum might be more meant for a diesel conversion question anyway.

Over the years my 4.0 has started to show its age and I've pondered the idea of doing a Mercedes diesel om617 swap. Well now my 4.0 is done and I bought a Mercedes 300D donor car as well as swap parts from Mercedesdiesel4x4 to adapt an ax15 to the om617 engine. My Xj came with an automatic aw4, which in its current state is in even worse condition then my 4.0. Over the years I considered a manual swap so I had a general idea of what parts I needed...However, its coming time for me now to make a choice on an ax15. There's a few for sale and Id like to make the best choice. What I need to know is are newer model ax15's at all controlled by the jeeps computer? Or can I pick up any one of them, bolt it up to my om617... and be on my way? Obviously an auto has much more interaction with the ECU and I even read that the 97+ model XJ's are much harder to convert from auto to manual. It seems to me as though those difficulties only really apply to someone who is keeping the 4.0 and In my case although mine is a 99, I will not have a 4.0 interacting with the ax15 and instead an 84 om617 turbo diesel.

The ax15 swap parts should be the last pieces to my puzzle for the om617 swap. What challenges will I face trying to make an ax15 work in my 99 XJ that was originally auto....or will I face hardly any as I am mounting it to an om617.

Some info I would like to put out there for people helping me are that for starters the jeep starter is still used with the swap. I will still be using the np231 transfer case which would indicate to me my speedo will work. I have an adapter for the oil pressure gauge to work and I will be able to modify the alternator so it works with the jeep wiring harness too. I'm imagining that the key is turned, starter spins, om617 comes to life and the computer reads nothing because the 4.0 isn't there. the key will fallback to the running position and my gauges will work, alternator will be charging and ill go on my way. (I wont be incredibly bummed if the tach doesn't work but I will attach the cps and see what happens)

Let me know what you think. All ideas brought to the table are appreciated. I've done a lot of reading on this swap and now the only thing tripping me up are some threads I read the other night explaining that the auto to manual swap on a 97+ Xj is much harder. Will I run into those problems?

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