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-   -   My first SYE Conversion (http://www.wranglerforum.com/f282/my-first-sye-conversion-155540.html)

WingingIt74 04-23-2012 04:59 PM

My first SYE Conversion
 
Any advice before I drop my skid plate?

ipleadda2nd 04-23-2012 06:20 PM

Make sure you have all the tools, ATF and RTV. Read those directions before hand as well. A hand pump is helpful to get the ATF from the bottle into the fill hole.

If you have any rust on the frame where the skid touches, now would be a good time to clean up and paint.

I didn't remove the tcase. I performed the work under the Jeep. I have since removed the tcase for other reasons. I believe either way is not that bad. IMO, leaving it attached to the tranny is easier, because you don't have to lift/fumble with it.

If you are removing the tcase:
  • You can let the tranny drop a little to get at the 2 topmost nuts holding it to the tranny.
  • If you have a tranny output shaft seal leak now would be a good time to replace the seal.
Some say to replace the tcase chain while you're at it. I guess mine seemed fine. I hear there is a major quality difference between cheap Chinese and US made chains.

And of course have fun! :)

And for God's sake, don't get any silicone in the new output shaft bearing housing drain passage! And make sure the speedo is fully seated with o-ring. These are common areas that cause leaks.

TnDz TJ 04-23-2012 09:22 PM

lockring pliers ( and snapring pliers)

12 point 10MM socket or wrench is REQUIRED for ONE BOLT.... no joke...

Common handtools..... you are set.

Well... fluids and RTV.

timberland 04-23-2012 09:31 PM

Search you tube for Advance Adapters video on the how to SYE.

chop110 04-23-2012 11:31 PM

I hope you didn't get the Rugged Ridge SYE kit. Those things are notorious for leaking.

WingingIt74 04-24-2012 07:45 AM

I just recently heard of Rugged Ridge... must be a new brand. No, I got a Terra. I got all my stuff from Rokmen, Jeff knows his stuff and has the patients to deal with a person like me that has enough knowledge to be dangerous :)

Do you think I should replace the clutch as preventative maintenance?

TnDz TJ 04-24-2012 09:19 AM

Quote:

Originally Posted by chop110 (Post 2295809)
I hope you didn't get the Rugged Ridge SYE kit. Those things are notorious for leaking.


Yup... mine leaked on day two.... National Seal #3946 cures their crappy seal issue. Plus I had to get a complete replacement SYE kit after I found out the main output shaft was milled wrong.... runout was about .003 and causing vibes... new one in and no issues... their good on their warranty and replacement parts were sent out pretty quick.

bcpaddler 04-24-2012 09:49 AM

Tom Woods built my SYE shaft as well as my rear drive shaft - no problems after installation. He also gave very good customer service while I was setting my rear pinion angle - he made something I thought was going to be very difficult into something my 15 year old could understand. Tom comes highly recommended.

Do you have rear upper control arms?

DevilDogDoc 04-24-2012 11:51 AM

Quote:

Originally Posted by WingingIt74 (Post 2296492)
I just recently heard of Rugged Ridge... must be a new brand. No, I got a Terra. I got all my stuff from Rokmen, Jeff knows his stuff and has the patients to deal with a person like me that has enough knowledge to be dangerous :)

Do you think I should replace the clutch as preventative maintenance?

Your still a far shot from having the tranny on the ground vs taking the TC off. If the clutch is fine I wouldn't mess with it. Hell you can do the SYE under the jeep with the case still attached if you wanted to. I would rather have it on the bench myself but some guys can do it from underneath.

bcpaddler 04-24-2012 01:44 PM

Quote:

Originally Posted by DevilDogDoc (Post 2297181)
Your still a far shot from having the tranny on the ground vs taking the TC off. If the clutch is fine I wouldn't mess with it. Hell you can do the SYE under the jeep with the case still attached if you wanted to. I would rather have it on the bench myself but some guys can do it from underneath.

Sorry, I failed to mention that I did mine still under the jeep... I just removed my skid plate and everything was pretty much accessible.

These are the best instruction for doing it while under your jeep IMO...
Advance Adapters Slip Yoke Eliminator AA SYE Jeep TJ Installation

Good luck.:thumb:

WingingIt74 04-30-2012 10:01 AM

Well, my first hurdle... On the skid plate, (1) bolt broke, (1) bolt came free and (4) bolts just spin.

Any suggestions?

DevilDogDoc 04-30-2012 11:39 AM

Your going to need to replace all the nutserts in the frame now. Not a hard job once you have the parts.

WingingIt74 04-30-2012 11:49 AM

OH THAT SOUNDS FUN! Especially since I don't have a welder. Where can I get the nutserts?

DevilDogDoc 04-30-2012 12:04 PM

Right here is all you need to know. Nutsert for Transfer Case Removal and Install - JeepForum.com

siafu 04-30-2012 12:31 PM

I am about to do my SYE install as well in a week. I have all of my ducks in a row (as much as I can think of). I have the Advance Adpaters SYE and the TW driveshaft. I purchased (not arrived yet) a set of RUACA's in case I need them for setting the pinion angle but some have said it is not necessary as every TJ is different. My question is about the rear track bar.

With my 3" lift from Zone, it came with the track bar relocation bracket. I read on another thread that I will need to change the bracket and track bar if I install the SYE and RUACA's. Is this true? Can I still use what I have or is the angle of the dangle going to destroy the stock trackbar/Zone mount?

If it will work as is, then I can wait on the adjustable track bar till a later date, but for now I want to make sure I am not going to damage anything by tweaking what I have.

DevilDogDoc 04-30-2012 12:56 PM

There is no maybe about the the rear uppers. The pinion angle will need to be set correctly for the DC shaft. The maybe is if your lowers will adjust out to allow the change in angle. As far as the rear trac bar you will want a DC bracket that is angeled and open or you may hit the tank when you stuff the rear suspension.

siafu 04-30-2012 03:34 PM

Quote:

Originally Posted by DevilDogDoc (Post 2318527)
There is no maybe about the the rear uppers. The pinion angle will need to be set correctly for the DC shaft. The maybe is if your lowers will adjust out to allow the change in angle. As far as the rear trac bar you will want a DC bracket that is angeled and open or you may hit the tank when you stuff the rear suspension.

Thanks for the reply!

ALjeep 05-01-2012 09:58 AM

I'll be watching this thread because I found out my recently purchased TJ has a 4" lift with no SYE thus I have a terrible vibration at 55+. I know I need a SYE but am apprehensive about doing it myself. In theory it doesn't look too hard but Murphy is always close by.

WingingIt74 05-01-2012 10:15 AM

I'm not in a terrible hurry, so if you have time... stay tuned. I'm going to start taking pics of the process as well and post them.

I ordered my parts from Jeff at Rokmen, great guy and out of the few shops I called, the only one that would take the time with me.

• Complete set of Rokmen adjustable control arms
• Currie Front Adjustable Track Bar
• JKS Rear Adjustable Track Bar
• TeraFlex SYE
• Tom Woods Rear CV Drive Shaft
• Tom Woods Front CV Drive Shaft (Mine needed repaired or replaced and was missing the slip yoke)



I'm going to cut the bolts tonight and drop my T-case.

ALjeep 05-01-2012 11:16 AM

Quote:

I'm not in a terrible hurry, so if you have time... stay tuned. I'm going to start taking pics of the process as well and post them.
No hurry here, mine is drivable as is as long as I stay off the Interstate, have to take an alternate way to work. I think I'll hone in on my A/C cooling problem for right now.

WingingIt74 05-01-2012 09:28 PM

Holy Cow... those bolts where tough... 3 sawz-all blades and one migraine later.

jrmiller 05-01-2012 09:33 PM

Good luck! I just finished mine up tonight, going to fill it up with fluids and start setting up angles soon. I took my t-case out for the install, mostly because my rear output seal on the transmission needed to be replaced. It was very easy to do and my only advice if you do remove the t case is to remove the front yoke before the t case is out......don't ask how I know.

ALjeep 05-02-2012 11:55 AM

Still researching my options and think I have it narrowed down to the SYE with new DS and adjustable UCA's or after talking with someone at Rough Country, they said I could probably fix the problem with only installing the adjustable UCA's which would be way cheaper (found a set for $149).
After looking at my DS angle, I am not fully convinced that the UCA's alone will fix my problem.

Any thoughts on these two options?

WingingIt74 05-02-2012 11:58 AM

I was told you need an adjustable track bar as well.

TnDz TJ 05-02-2012 12:41 PM

Quote:

Originally Posted by WingingIt74
I was told you need an adjustable track bar as well.

Not necessarily. Depending on size of lift. I have a 4" lift, SYE and stock trackbar. What makes the stock trackbar work is te angled cv trackbar bracket. Only two are made that I know of... JKS and Rubicon Express. I have the RE1602 and works great. If you have a lesser lift, yes the adjustable trackbar would most likely be needed with a straight trackbar bracket

WingingIt74 05-02-2012 12:50 PM

besides.... I plan on doing an OME lift and a belly up.

WingingIt74 05-20-2012 09:53 PM

I finally got the t-case dropped. I will take more pics as I go along. I have it on jack stands so I can drain the oil.

http://sphotos.xx.fbcdn.net/hphotos-...03368327_n.jpg

siafu 05-20-2012 11:20 PM

Quote:

Originally Posted by DevilDogDoc (Post 2318527)
There is no maybe about the the rear uppers. The pinion angle will need to be set correctly for the DC shaft. The maybe is if your lowers will adjust out to allow the change in angle. As far as the rear trac bar you will want a DC bracket that is angeled and open or you may hit the tank when you stuff the rear suspension.

Well, it ended up being a Maybe like I said. SYE complete and NO adjustable uppers needed. My pinion to DS angle is about 3 degrees different (I know 1-2 is recommended but.....). I have the uppers on the way since I bought them with everything else, but there are NO vibes at all and the ride is crazy smooth now. I had no idea a lot of what I was feeling was all fixable with the SYE and Tom Woods DS kit. That and the silly TC drop is now gone which looks much better.

WingingIt74 05-29-2012 09:45 PM

Cracked open the T-case this evening with my 11 yr old son. A learning experience for both. Just noticed they forgot the new lock ring for the gear set. I'll have to get a hold of them tomorrow to get one in the mail.

http://sphotos.xx.fbcdn.net/hphotos-...10213351_n.jpg

Everything has been pretty straight forward. A good video to watch is this one from Advanced Adapters.

Jeep New Process 231- NP231 SYE Install - Slip Yoke Eliminator - YouTube

Good to watch the video a few times prior to actually doing the SYE.

sandro 06-02-2012 09:56 AM

wow... thanks for all the pics, looks like a lot of work! I want to do this to mine


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