AW4 output shaft housing differences?

[DSM]

I posted this topic on pirate4x4 and those guys told me to come see you guys. :thumbup:

My Montero Sport comes with the same AW4 trans that you guys have.

It simply has a different bell housing and output shaft housing bolted onto it, im doing a solid axle swap and switching to a NP231 tcase, for this i need a jeep AW4 tailshaft housing. Currently i've narrowed it down to a 98+ so that i can retain my speed sensor for the transmission.

Would anyone with a 98+ AW4 be willing to get me some pictures of the housing & sensor orientation? Or heck, anyone willing to sell me a 98+ outputshaft/tailshaft housing???

Any input on the year changes and sensor output signals would be great.

the one on the top (black) is a 97 Mitsubishi, goes in the tailshaft housing of the AW4, the blue one was in the tail housing of the jeep, the jeep i stole this from is a late 80's early 90's, the sensor for a 98+ jeep looks just like mine sans the wire harness, so hopefully i can just put mine in the jeep housing


Sorry for the wall of text, on to the pics;

both are 2 wire but the jeep one is 3 "prong" (IIRC)..

According to Rock Auto, this is what the sensor from the 98+ jeeps look like.

AIRTEX Part # 5S4764

other pics related to this

mitsushitty transfercase, otherwise known as the gigantic useless piece of shit.

Trans still in the truck without the tail housing on it.

jeep on the left, mitsu on the right, mitsu is freaking over kill

jeep on the left again, gee, they look similar.

5 of the 7 bolts for the tail shaft housing require the tcase to be removed to get to them on the mitsu hosuing, on the jeep housing they're all external

backside of jeep one

some of you might recognize the gent in this picture, he wheels down at the bad lands often. :wave1:

his rig has substantially more body damage now vs when this pic was taken. Hahaha.

 

[lawsoncl]

From my reseach, 98 was the year the Jeep AW4 rear sensor changed and they added the front input shaft sensor. The rotor for the rear sensor prior to that only had 1-lobe and triggered a magnetic switch in the sensor 1 pulse per revolution (think of a switch opening and closing). After that it had 4-lobes and the sensor produces 4 voltage spikes per rev (like a pickup coil when a magnet passes by).

In your picture, the long skinny one is the reed-relay type used in the pre 98 Jeeps. It doesn't physically fit into the newer trannies as I found out when trying to swap a 99 into an 89. Your shorter sensor does look just like the sensor used 98+ with the 4-lobes. I can't quite tell in your picture, but it looks like you have 4-lobes there? I'm guessing the year split is the same for the Monteros and the sensors are identical.

 

[lawsoncl]

Just had another thought. You have the tail housing from an early Jeep that used the longer sensor. Have you tried bolting that up and seeing if it holds the Mitsu sensor in the right spot?

 

[DSM]

Yeah my 'trigger wheel' is a 4 arm 'flywheel' style thing. Where as like you said the older AW4 uses the lobe. I'm hoping someone can get me a picture, i may drill this housing otu to put my sensor in it but i'd like to put an OEM housing on it that will work.

I wish i had more time to go to the junkyard, if anyone knows someone that may have some 98+ trans parts, please have them get in touch with me.

 

[DSM]

Just had another thought. You have the tail housing from an early Jeep that used the longer sensor. Have you tried bolting that up and seeing if it holds the Mitsu sensor in the right spot?

the mitsu sensor is too large in diameter to fit into the older jeep housing, it holds the sensor on the opposite side of the trans and is quite different. would take a little 'retrofitting' :twak:

 

[DSM]

Someone has to have at least one 98+ torn apart right now...?

 

[lawsoncl]

the mitsu sensor is too large in diameter to fit into the older jeep housing, it holds the sensor on the opposite side of the trans and is quite different. would take a little 'retrofitting' :twak:

Ah, gotcha. Hence the request for the Jeep version. I think the Jeep one is going to be the same OD as the mitsu one. I do remember the 99 sensor was bigger diameter and shorter than the 89 one.

 

[DSM]

yeah, the one picture i posted above of a single sensor close up is an actual 98+ jeep sensor, looks a lot like the mitsu one.

I tried putting the older jeep tail housing on and the 'flywheel' for the speed sensor on the output shaft hits the older style housing so i 100% need a 98+ housing at least so it will clear the sensor wheel..

I just wish someone could get a quick pick and measure a couple things for me.