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Old 01-06-2009, 03:43 PM   #1
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transfer case help

ok well i got my rear end swap done and got a d35 with 4:11 gears and it helped with the top end speed problem i was having with the 3:07 gears but now there is a popping sound after driving about 15 to 20 miles, so last night i pulled it into the garage and took a look at the the back of the transfer case and noticed a thin spring all the way around the drive shaft, so i thought of course the rear oil seal went out so i removed the drive line and looked in side and noticed bearings missing from the bearings right before the transfer case oil pump, so now i'm thinking the popping noise i heard was the missing bearings in the gear housing maybe, i removed the drive line and then put it in 4x4 and low side works but the high side is gone, i'm not using the 4x4 right now because i haven't re geared the front yet, so do you think i could just replace the oil pump housing bearings and the rear oil seal and try to remove all the old loose bearing and still run it? if so how do i remove the loose bearing flying around in there? could i remove the oil pump housing to get to them or is there a easier way to do it? before everyone tells me i must have done something wrong for this to happen, keep in mind the old rear end got torn apart in it, so i think it could have done most of this damage when it went out and i just didn't take the time to inspect it good enough, which was a mistake because the high side of the 4x4 was working when i switched the rear end out. man this as been a expensive job. lol. 400 bucks for the first rear end and then it got stolen and then 500 bucks for the 2nd rear end, new shocks, u bolts for the springs, new brakes, brake calibers, flaring tool, gear oil, paint, and so on and so on. lol. but i love my jeep.

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Old 01-06-2009, 05:04 PM   #2
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The best way to get all the crap out would be to crack open the case and yank all the guts out. Then go over everything with some carb cleaner and a clean plastic bristle brush. I wouldn't just replace one bearing. If your going to have the case open you should replace all the bearings and seals.

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Old 01-06-2009, 05:19 PM   #3
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Jeep Articles / Technical and Installation (Rebuilding The 231: Assembly) - MoabJeeper Magazine

Crown Automotive - NP 231 Transfer Case

This is where I got my parts to do mine,If you plan on doing a SYE in the future this would be the time.
hope it helps.
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Old 01-06-2009, 06:52 PM   #4
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Quote:
Originally Posted by scrambler1 View Post
Jeep Articles / Technical and Installation (Rebuilding The 231: Assembly) - MoabJeeper Magazine

Crown Automotive - NP 231 Transfer Case

This is where I got my parts to do mine,If you plan on doing a SYE in the future this would be the time.
hope it helps.
ok so if i go this route and just go ahead and do a complete over haul of the transfer case and do decide to go with a sye, what is involved with doing that? would i have to get a different drive line also? i have never done a overhaul of a transfer case, on a scal from 1 to 10 and 10 being the hardest how hard of a job is this? could someone who has never done one be able to do it?
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Old 01-07-2009, 05:39 AM   #5
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Do a little checking around before you start rebuilding, I just found a great 231 off a local craigslist for $100, couldn't even have started a rebuild for that price!
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Old 01-07-2009, 08:29 AM   #6
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Yeah Id replace all the bearings and seals too, while its open get it all switched to new or just buy a new (used) one either way thats what I'd do.
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Old 01-07-2009, 10:41 AM   #7
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Thats another option to get a used transfer, Never know what you are going to get.Always comes down to money. If you do plan on picking up a used transfercase and you swap it in you can always later on rebuild your's if needed, it is already out. If you do plan on doing a SYE here is a great write up on how to do it,This is the what I used

http://www.wranglerforum.com/f8/sye-...-1-a-5266.html
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Old 01-08-2009, 01:10 PM   #8
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if you did not remove the front drive shaft before you ever moved the jeep , if you drove it even in 2wd with out changing the front ratio you have done damage
you may be lucky and only damaged part of the transfer ,i've seen pinion shafts broke ,axles snaped ,transfers explode all because of wrong ratio in one axle , and even mismatched tire sizes can cause damage
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Old 01-09-2009, 10:51 AM   #9
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Quote:
Originally Posted by asbury View Post
if you did not remove the front drive shaft before you ever moved the jeep , if you drove it even in 2wd with out changing the front ratio you have done damage
you may be lucky and only damaged part of the transfer ,i've seen pinion shafts broke ,axles snaped ,transfers explode all because of wrong ratio in one axle , and even mismatched tire sizes can cause damage
I'd have to disagree, in a YJ as long as you stayed in 2wd there should be no problem as the front axle is freewheeling, put it in 4wd though and yes something is probably going to break.

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