A np241 from a th400/4l80e would have the 32 spline that is need for a manual trans, one from a 700r4/4l60e is 27 spline input, in 94 the switch was changed and the cam to activate the switch was changed so if you get a 94 np241 you then will need to wire in a 94 switch into the older harness
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Yes for the 366 since it is a MKIV like the 454; the difference is the taller deck making it taller and wider, but I would expect there is plenty of room in the C/K engine bay for the taller deck 366 MK IV. Note the 366 also takes a different intake than the short deck MK IV.. What 5 speed is it. The 5 speed may (very likely will) be different than the 4 speed that came in the truck. Since you have a 4WD, the location of the output of the 5 speed vs-a-vis the 4 speed is quite important. You may be looking at altering location of the transfer case and changing the length of both drive shafts from the transfer case to the banjos. If you have a drive train specialty shop in your area I would get their input on the changes (cost) involved in the possible drive train changes required by the length difference between the 5 speed and the 4 speed gearbox.
Transfer case fluid is different from the trans fluid, transfer case takes a Blue fluid made by G.M. can't think of the name of it, and trans takes Dex III or IIII read manual, if it is getting to transfer case then you deal between the trans and transfer case is bad causing it to **** the fluid out of trans, need to change the seals this time. Car Quest sells a 1 piece seal that seals both units instead of 2 different seals. Good Luck
Not without using the chevy transmission (and transfer case if it's a 4WD Mighty Max), Custom Motor Mounts, Custom Transmission Mount, Wiring Modifications, Driveshaft Modifications (either lengthened or shortened, depending on where the transmission or transfer case is located). Possibly shifter hole modifications (if it's a 5-Speed Manual), or Custom Linkage/Linkage Modifications (If it's an Automatic)
Sounds like a bad out speed sensor.Are you sure you replaced the correct sensor?This trans(AW340)Has an output speed sensor and a vehicle speed sensor.The output speed sensor is located on the side of tail housing just next to where it bolts to transmission case.The vehicle speed sensor will be about midway of the tail housing or on the transfer case tail housing on the 4x4 models.It may be a good idea to have a tranny shop you trust run a diagnostic and see if you are getting output sensor signal to TCM( transmission control module behind glove box)and take a look at TPS (throttle position sensor)signal when it is hot to make sure you replace the correct part.I have seen bad TPS sensors on these jeep not affect engine drivability because the sensor is really two(one for trans and one for engine)thus the two plugs on the TPS sensor for the automatic Cherokee.Good Luck and let me know if I can help.