Ive seen post, write up's and discussions about swapping a 2wd to 4wd a majority of them if not all were all on automatics, not too many if any on 6 speeds. So after scoring a pretty good deal on my JKU (it was a 2WD) I decided to tackle the swap. The one thing about a 2WD is that you know for a fact that its never been wheeled hard or anything, plus really low miles sounds decent enough to me. Big shout out to my dad for coming over for the extra hand due my physical limits, pretty limited to what I can do or lift, the joys having a awesome limp....
and for the endless fridge full of
Anyways, SO parts list:
F&R drive shaft $200ish cant remember
New Main shaft for transmission $450~ Price varies MOPAR #5159163AA
Snap Ring $1.99 5098788AA
Rear Transmission Seal 5099840AA Same part number as the front seal
T-case shifter cable 52126222AD $98
T-case knob $24 52060451AF
Shift cable Bracket $19 52121832AC
$1,400~ minus regear
Plus what ever gears you want to regear to, the choice is yours! Me I went with 4.10's.
Now that's all the basic stuff you need to get it to 4WD, We added some other goodies well just because fridge was still full and were in this deep might as well. Added XD addict 18's wrapped in Falkin AT's, Fox shock w/ 3 in lift, synergy hood louver, drake hood hold downs, super chips pac and so on...
The biggest issue I ran into was the transmission. As stated above you HAVE to replace the main shaft in the transmission. It's basically a direct swap take out the old shaft and put the new one in, difference between the two is one is for a 2WD so its shorter, and the other is for a 4WD which it is longer and has the spline for the Tcase to hook onto. If you have the problem of 1st gear popping out like in the early JK's with 6spds putting a new shaft in will only amplify the problem so you have to replace 1st gear, or what ever gears your having the popping out issue. I had to replace first gear because it would not even go into first. The transfer case is a direct bolt on to the transmission. As far as the wiring for the Tcase hasn't been a issue for me but would like to get it hooked up someway proly one day, Just do the ESP mod or the steering wheel hokey pokey. ESP mod is what I did and no problems
So was it really worth the time and $$ ? I say yes. Other people may say no or will look at you like your a bit off your rocker, or just tell you to trade it for a 4wd but that would just take the fun out of it all! depends on what you want and want to do with your rig.
Oh and if you call the dealer to reference part # they will most likely tell you "why do you want to do that"
After you do all that you have 4WD