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tj_guy99 02-22-2012 09:20 PM

Drive Shaft - SYE - Transfer Case Chain
Ok, I remember why I was reluctant to get started with the whole Jeep modification thing. Late last year I decided to upgrade the D35 with a D44. I checked into junkyard swaps and combos with the front so I would have the same bolt pattern. I came across a Bronco 9" rear D44 front combo but would have had to change the gears and I didnt want to have drum brakes all they way around. I decided the best way to go would be to drop the money on the rear G2 D44 with Discs. I was going to save money on the front and only regear. I found that I do NOT have the 3.73 gears, I have 3.07 gears :facepalm: That means I had to buy a new carrier. I also found out that the drive shaft was too long on the back. I decided to pop for the SYE (which is where I wanted to end up) for only a few hundred $$ extra. All of that was background info for where I am going next.

My question is this: Should I change the transfer case chain while I am having the SYE CV shaft installed? Everything that I read says to change it at 50-60K miles and I have about 112K miles. Also, how hard is it to change the angle of the rear to line up with the output shaft from the SYE?

The good news is that when this is all said and done, I will have a more capable Jeep with 33" tires, a D44 rear with an OX locker and disc brakes, and 4.56 gears :dance: for $500 -$600 over budget :nonono:

Vermaverick 02-22-2012 09:26 PM

I just did a SYE on my 98 tj, you HAVE to go all the way in to the point of removing the chain any way, so I figured, just as easy to put a new chain back in, it was 67 bucks from

BTW, mine was at 102K when I did it, and there is seriously less noise when I shift now, much MUCH smoother.

I say go for it, and don't Look back!


tj_guy99 02-22-2012 09:28 PM

Thanks Doug, that is what I was thinking but looking for reassurance from those that have already done it. Were there any special tools or any problem that I can expect to run into?

doclouie 02-22-2012 11:41 PM

I have heard that you need some good snap ring pliers that are larger than normal ones. I will be watching this thread as I am close to the same boat you are in.

Ricterslick 02-22-2012 11:54 PM

3 Attachment(s)
Having just done this I will ring in. I didn't have snap ring pliers so I picked up a set. They we're too small and I chased those dumb snap rings around for hours until I saw there were new ones in the kit. Then out came the needle nosed vise grips and I ripped them off. They have done this like 5 times on Spike tv's 4x4 show. Go to their page and watch one of the videos. Did it in over a weekend. Wait at least 24 hours before you add the fluid in to give the sealant time to setup. Good luck

geiman 02-23-2012 08:16 AM

Haven't replaced the chain in any of the SYE installs I've done, all of which were over 100K. I've had no issues thus far; the chain has always been in good condition.

But if you want to spend the money, it's certainly not a bad idea. I believe you can get a kit that comes with a new chain and a few other parts to "freshen up" your t-case. You should have good results either way, just depends on what you want to spend.

Vermaverick 02-23-2012 09:29 PM

I agree with Ricterlsick, The only hassle I had also was the dang snap rings, I ended up just destroying them also.

Be carefull with the pump pick up staying put and slowly work the kalves back together, I just turned the front yoke back and forth to "jiggle" things into ligning up, no sweat.

Good luck!

If you have Lift, don't forget to remove the silly Skid Plate spacers and enjoy the extra 1.5" of new ground clearance.


tj_guy99 02-23-2012 10:32 PM

Thanks for the input! Yeah, I cant wait to lose the skid plate spacers and gain some ground clearance in the middle. I am a litle worried about getting the pinion angle set. I am not sure how I will get that done and my jeep is still at the local junior college where the work is getting done. I need to see just exactly how that all works before I turn them loose on the SYE. I am just ready to have it all done and back in my driveway.

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