NV4500 Transmission Conversion
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The first thing i must suggest to you if you are having problems with your AX-15 is, don't fix it, don't replace it with another AX-15. The AX-15 is clunky outdated and has a wide range of weird problems.

I have done a lot of reading up on this subject, and it turns out the most common heavy duty gearbox which can fit into a wrangler is the NV4500 from a dodge.

I Contacted a company called Man-Trans located in Florida and ordered my self a conversion package which includes a remanufactured NV4500, a remanufactured NP231 transfer-case, slip-yoke eliminator, bell housing, External slave cylinder kit and shift-stub for my wrangler. The best part is the 1 year unlimited Mileage warrantee. All for US$ 3285, and it comes all ready assembled.

I found the employees at Man-Trans to be ready to help, and they customize the gearbox for your setup.

On this page I will cover how to remove and install a gearbox on your wrangler.

My gearbox arrived, at the moment I am still installing it, but I hope to finish this page realy soon. For now I have added some picks to entertain you.

Removing the old Transmission

My car lifted on bricks  NV4500 just arrived

Slip-Yoke Eliminator NV4500

NV4500 in front of my jeep                                  Included Modifying parts

4X4 Linkage                                                             Linkage Extended by 30mm

Fitting the new linkage                                               Removed drive shaft

Support rear of transfer case                                 Remove cross member

Disconnect vacuum switch                                      New Clutch Fork and Bearing

Supported ready to be lowered                                           Disconnect Clutch line

Rear jack stand support Disconnect breather

Remove the Crank Sensor Disconnect Speedo Sensor

Disconnect reverse switch Separate engine and transmission

Lower transmission Moved out of the way

Installing the new Transmission

Old clutch removed Gearbox moved closer

New clutch and pressure plate 0.5mm clearance from chassis... lol

NV4500 lifted into place Clutch master cylinder

Once the gearbox is bolted to the engine and all the bolts are torqued. Jack the gearbox up to the correct hight and place a support at the end, to hold it in place. Now place the crossmember in its origional location and mark which parts need to be cut or drilled. Then cut out the sections which catch and drill the holes for the new mounts. Reinstall the cross member and check for atleast 8mm clearance along the front of the transmission and 1cm at the back and 1.5cm around the mounts and sides of the transmission. When all the clearances have been checked, weld extra support to the crossmember to make sure it does not bend under the new transmissions weight.

The new bell housing requires you to change your clutch system to an external hydraulic clutch. You get a new slave cylinder, hose and fittings for the new setup. You have to remove your master cylinder push out the pin pull out the origional hose, push in the new hose connection and reinsert the holding pin. Reinstall your master cylinder and connect the new hose.

Changing fitting New Hydraulic cable

External Slave Cylender Clutch Slave Cylinder

Now, you should notice that when you do a conversion like this, you would no longer be able to use your stock drive shaft. I ordered a brand new drive shaft from Qaudratec cost me about $400 but is worth it.

Shiftboots, and making it all look nice

Stock ShiftBoot Stock ShiftBoot

Stock ShiftBoot Holder Stock Dust cover

New Shifter location New Shifter Location

New Shifter Location New Shifter Location

Due to the new location of the Transmission and Transfercase shifters, I can't use the stock shifter boot. I also had to grind off a bit to accomadate for the Transfercase shifter, which means that I will have to move my center console back about 1". I have started manufacturing my own shift boot, along with the shiftboot frame.

New Shifter Location New Shifter Location
New Shifter Location New Shifter Location

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Page Index:
1.) About my Car
2.) Camping Trips & Duning
3.) Sound System & Bluetooth.
4.) Effects and Neons.
5.) Magna Donnelly Rearview Mirror.
6.) Power Windows & Central Locking.
7.) HID Xenon.
8.) Garmin GVN-52.
9.) Auxiliary fuses.
10.) Custom Side Mirrors.
11.) Custom Electronics & Wiring.
12.) NV4500 Conversion.
13.) Performance.
14.) Custom Power Top.