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Old 06-11-2014, 06:25 PM   #1
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Blew up my Rubicon's NVG 241OR Transfer Case - Options?

My 2003 TJ Rubicon's transfer case blew apart when I was driving down the highway at 70MPH, it was phenomenal.

Now I'm searching for a replacement. I found a 'new'ish one for $2,500 from JB Conversions JB Conversions, Inc.

I also found one used through a salvage yard with 58k miles on it for $1,400.

It's at a shop now - so what are my options? Does anyone have one for cheap? Is there anything else I could swap in somewhat easily (read: have this mechanic shop in Abbotsford, WI do it and not charge out the wazoo) that would be better / cheaper / more easily available?

I regularly beat the hell out of it and enjoy doing so, so downgrading to a NV 231 doesn't sound like a good option, should it even be possible.

Advice?
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2003 Jeep Wrangler Rubicon (Black)
Stock 16" Moabs with 265/75R16 Goodyear Authoritys
Herculined Tubular Bumpers with 2" Receiver welded
Fun safety-override switch (start w/out clutch & engage lockers in any transfer case position)
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Old 06-11-2014, 07:00 PM   #2
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Wow that was dramatic, I think I'll run out and change my 241's ATF tonight.

I think I'd probably go with the one from JB Conversions who has a very good reputation. See if you can get them to throw in some kind of warranty.

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Old 06-11-2014, 07:39 PM   #3
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Have you checked to see if the front drive shaft double cardan joint seized and caused this?
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Old 06-11-2014, 07:52 PM   #4
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I haven't checked the cardan joint, I will check shortly.

What are viable alternatives for this transfer case in a 2003 TJ (read: not downgrades)? Atlas II for $2,360 from Build Your Atlas | Advance Adapters ? Anything else?
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2003 Jeep Wrangler Rubicon (Black)
Stock 16" Moabs with 265/75R16 Goodyear Authoritys
Herculined Tubular Bumpers with 2" Receiver welded
Fun safety-override switch (start w/out clutch & engage lockers in any transfer case position)
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Old 06-11-2014, 07:56 PM   #5
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I'd stick with the 241. It is normally a very good/strong t-case with a great 4:1 ratio. Yours is the first I remember seeing come apart like that.
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Old 06-11-2014, 08:52 PM   #6
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That damage is consistent with a front double cardon joint seizing at freeway speed. What ever you swap in make sure to check that joint.
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Old 06-11-2014, 09:17 PM   #7
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Well, at least you rust-proofed the undercarriage for the next 3 months or so...
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Old 06-11-2014, 10:35 PM   #8
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Is the 241OR really the 'best' t-case for these? Or are other ones (like the Atlas 2 / 4) just too much work or very little gain?
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Old 06-11-2014, 11:24 PM   #9
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Its pretty darn hard to beat. Unless you want a lower ratio or will be pumping more power with a bigger engine, I see no need for an atlas.
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Old 06-12-2014, 12:12 AM   #10
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... but if I find an atlas cheaper than a 241OR, get it?
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2003 Jeep Wrangler Rubicon (Black)
Stock 16" Moabs with 265/75R16 Goodyear Authoritys
Herculined Tubular Bumpers with 2" Receiver welded
Fun safety-override switch (start w/out clutch & engage lockers in any transfer case position)
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Old 06-12-2014, 12:13 AM   #11
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(very little we do is about 'need' around here)
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2003 Jeep Wrangler Rubicon (Black)
Stock 16" Moabs with 265/75R16 Goodyear Authoritys
Herculined Tubular Bumpers with 2" Receiver welded
Fun safety-override switch (start w/out clutch & engage lockers in any transfer case position)
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Old 06-12-2014, 12:16 AM   #12
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Originally Posted by Ehryk View Post
... but if I find an atlas cheaper than a 241OR, get it?
The Atlas is not an easily installed bolt on product, I don't believe it's characteristics make it worth the additional time and effort required to replace a 4:1 241 with it.
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Old 06-12-2014, 09:36 AM   #13
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I've wanted a 4 speed atlas bad. I want something like a 1:1 for steet, 2:1 for sand and mellow trails, 3:1 for rocks, and 5:1 for big rocks. My 4:1 is too much for easy trails. If mine blew up, I would go atlas for sure. I had the squeaking drive shaft, and removed the shaft because of the horror stories like this where the joint freezes and blows up the T-case. I put all new U joints in and it's good to go. Did you hear a 5mph squeak?
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Old 06-17-2014, 09:09 AM   #14
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Is the 241OR really the 'best' t-case for these? Or are other ones (like the Atlas 2 / 4) just too much work or very little gain?
I was going to put in a 241OR and decided instead to put in an Atlas II 3.8. Easy to put in. Needed a longer rear driveshaft and shorter front driveshaft... $200 for both at a local drive shaft business.

It runs flawlessly. I love the twin stick feature.

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