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Old 01-05-2016, 04:16 PM
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2015 JKU transfer case swap - sport to rubicon

I plan on building a 2015 or 2016 JKU with dana 60's and it makes sense to me that I should start with a Sport rather than a Rubicon because of initial cost. However, I want the 4:1 transfer case that the Rubicon has. Does anybody know if the cases are easy swaps? Shifter linkage/cable/wiring all reusable? I'm not overly concerned with output yokes or driveshaft length changes since I'll have to address all that with the D60 axles.

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Old 01-05-2016, 04:35 PM   #2
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From what I understand all the manual JK TC's are interchangeable but if you get an auto you will need a 4:1 TC from a 2012+ auto only. You will also need a Flashcal or similar to program the ECU for the new ratio, which is very simple.

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Old 01-05-2016, 06:18 PM
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More details...

I'm definitely going with an auto. I'd also like a new or super-low mileage transfer case. I've heard that the 2012 tc is different than the pre-2012, at least when connecting to an automatic. I haven't read anything explaining what the differences are. I'm going to continue researching it.

A bit off-subject but I'm also not familiar with the differences on the interior. I'm hoping the shifters are completely compatible. If I go with the Mopar Dana 60's I get the electric Easton lockers. I'd love to get the Rubicon dash switch module for the lockers. I'm assuming the Sport has a blank insert in the dash where the switches go. I'm going to have to go to a dealer and look at them.

What is motivating me here is that when I compared JKU Sport to the JKU Rubicons, the Sport is about $6,000 to $7,000 less. That goes a long way to paying for $11,000 axles. Since I'm not keeping the Dana 44 axles the remaining feature differences seem to be just the 4:1 TC and the sway bar disconnect mechanism. Certainly the Dana 44 axles that come with the Rubi are nice but I'm hoping to go with 37" tires and from what everybody says, that's the limit for them. The Mopar/Spicer D60's look amazing. Relatively easy install, great strength, and huge brakes. It looks like all I'd ever need in the axle/breaks department.
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Old 01-05-2016, 09:51 PM   #4
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One thing that is nice about the 2012 and up Rubicons with the auto is that, when in 4-low, they are programmed to start out in 2nd gear. This is nice to be able to get some wheel speed right off the bat instead of having to rev out in 1st before the trans shifts. In certain types of off-road, this really helps. If you want to really crawl, then tap the shifter over into 1st and the crawl ratio comes alive.

Perhaps, if you got a Rubicon, you could sell the factory fresh axles with lockers and swaybar disconnect system to help recoup some of the cost. Although you will still be money ahead on the Sport.

Another opinion: with the Ultimate 60s, you can easily run 40s.
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Old 01-05-2016, 10:21 PM   #5
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I did the sport to Rubi case in my 14. With a 15/16 auto you'll just have to find a TC from a 12-16 Rubi (spend a little extra for a low mileage). Also, since you might as well do it right the first time, I'd get the advanced adapters cable upgrade (just bought mine) and the RSE TC armor (that sandwiches the TC and pictured on my rig). I got lucky and found a 50 mile TC out of a 14 Rubi.

The swap was easy and my advice would be to drop the tranny cross member...I wasted 4 hours trying to avoid this step. Once it was out, it took 7 minutes to removed and put the new one in. I bought the flashpaq to change my TC ratio but I still hear conflicting advice on whether you actually have to do this. If not, I'd throw the flashpaq in the trash and use the traildash as my gauges/gear changer ect.
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Old 01-05-2016, 10:36 PM   #6
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Exactly what I did..
Don't know how difficult it was but it could not have been that tough because my shop did it in an afternoon.
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Old 01-05-2016, 10:49 PM   #7
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Can the flashpaq program the case to start off in 2nd like a factory rubicon? Sounds like a great thing
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Old 01-06-2016, 12:34 AM   #8
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If your putting in D60's why not spring for an atlas transfer case?
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Old 01-06-2016, 01:06 AM   #9
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Originally Posted by TIPN_OVR View Post
A bit off-subject but I'm also not familiar with the differences on the interior. I'm hoping the shifters are completely compatible. If I go with the Mopar Dana 60's I get the electric Easton lockers. I'd love to get the Rubicon dash switch module for the lockers. I'm assuming the Sport has a blank insert in the dash where the switches go. I'm going to have to go to a dealer and look at them.
The panels are different, but I don't think it would be too terrible expensive to get a replacement panel from a Rubi with the slots for the switches. You can buy the switches themselves separately.... However, I think because of the canbus system, those switches will render useless to an after market locker.
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Old 01-06-2016, 01:33 AM   #10
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The rubicon switch board is in a difficult to reach spot anyway. Pillar mounted FTW
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Old 01-06-2016, 06:51 AM
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One thing that is nice about the 2012 and up Rubicons with the auto is that, when in 4-low, they are programmed to start out in 2nd gear.
This is news to me, very interesting.

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Originally Posted by MCE Mike View Post
Perhaps, if you got a Rubicon, you could sell the factory fresh axles with lockers ... to help recoup some of the cost.
Yes, this is definitely something that I'm considering. Is there any reason I wouldn't want to keep the sway bar disconnect system on the Rubicon? I think it would be great provided it works with the D60's.
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Old 01-06-2016, 07:24 AM
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If your putting in D60's why not spring for an atlas transfer case?
That is being considered, as is just sticking with the stock transfer case in the Sport. I'm looking into the strength differences between the Sport TC and the Rubicon TC but almost nobody seems to bring it up, so I am thinking that the two must be very similar in the durability department, it's just the gearing that separates them.

As all you guys know, it's all compromises between time, money, and what you want to build. If I go with the Sport, I can spring for the D60's, lift, wheels, and tires, etc. all in one shot. If I get the Rubicon, I can't. With the D60's requiring 8 on 6.5 bolt pattern I don't want to buy the wheels twice, so what do I do? I'm really sold on the Mopar/Spicer axle package because of the "factory-ness" of them when it comes to serviceability.

The "have-it-all" option would be to drive a really nice stock (God forbid!) Rubicon around for 6-12 months waiting to accrue enough dough, but I'm afraid life would get in the way during that time and the funding for this project would get used someplace else and the dream will die.
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Old 01-06-2016, 07:27 AM
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The rubicon switch board is in a difficult to reach spot anyway. Pillar mounted FTW
Great idea! I don't mind creating a Jeep that looks like a monster from the outside but I like the inside to look clean and "factory". I've seen some nice pillar mount switch pods that should fit the bill, I just never considered them for the lockers before.
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Old 01-06-2016, 07:33 AM   #14
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Originally Posted by YamahaDOC View Post
Can the flashpaq program the case to start off in 2nd like a factory rubicon? Sounds like a great thing
I have been looking for an answer on this one but not found it yet.

If possible i would contemplate the swap.
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Old 01-06-2016, 07:40 AM
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Can the flashpaq program the case to start off in 2nd like a factory rubicon? Sounds like a great thing
It doesn't look like it. The feature list doesn't mention the transmission at all.
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Old 01-06-2016, 07:48 AM
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AEV's ProCal Module

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Originally Posted by YamahaDOC View Post
Can the flashpaq program the case to start off in 2nd like a factory rubicon? Sounds like a great thing
Check out the the AEV Procal. It addresses shaping transfer cases.

AEV's ProCal Module now features an all-new Transfer Case Calibration function that allows customers to install a non-stock transfer case into their 2012+ JK Wrangler (w/ A580 trans) without causing the vehicle to go into limp mode. This includes 2-speed Atlas transfer cases as well as Chrysler's Command-Trac NV241 (Sport/Sahara) and Rock-Trac NV241 (Rubicon) transfer cases.This new feature is only found on the latest version of the ProCal Module (part number 30406007AG). As of 2/18, all ProCal Modules being shipped from AEV are the latest version and include this function.
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Old 01-06-2016, 08:08 AM   #17
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Since you have deep pockets have you considered an Atlas transfer case instead of the stock Rubicon case? Go with the 4.3:1 or 5:1 low range.
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Old 01-06-2016, 08:13 AM
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I got lucky and found a 50 mile TC out of a 14 Rubi.
If you wouldn't mind sharing, how much did you pay for that transfer case? I think that new from Mopar they are around $2,200 and the Atlas is north of $2,800 if memory serves me right. For an ultra-low milage TC, if you beat those prices I think you did well.
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Old 01-06-2016, 08:47 AM
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Crawl Ratios

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Since you have deep pockets have you considered an Atlas transfer case instead of the stock Rubicon case? Go with the 4.3:1 or 5:1 low range.
5:1 with an automatic seems a little crazy. I should really drive an automatic Rubicon in 4-low to get a feel for what that's like.

Here is what I get for crawl ratio (with 4.88 gears in the D60's)
Sport 3.59 x 2.72 x 4.88 = 47.65
Rubicon 3.59 x 4 x 4.88 = 70.00
Atlas 3.59 x 5 x 4.88 = 87.60

I own a CJ7 with a 103:1 crawl ratio but it's a manual. It's great because with the clutch out it just creeps at idle. With an auto I'm not sure how a high crawl ratio behaves. It would be nice if the torque converter locked up at 600-700rpm when in 4-low. I was starting to think that being an auto, perhaps the high get ratio of the Sport TC might not be bad. I live in Wisconsin and there aren't many rocks to crawl. However, I dream of getting this truck to Utah and Colorado at least annually.
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Old 01-06-2016, 09:33 AM   #20
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Check out the the AEV Procal. It addresses shaping transfer cases. AEV's ProCal Module now features an all-new Transfer Case Calibration function that allows customers to install a non-stock transfer case into their 2012+ JK Wrangler (w/ A580 trans) without causing the vehicle to go into limp mode. This includes 2-speed Atlas transfer cases as well as Chrysler's Command-Trac NV241 (Sport/Sahara) and Rock-Trac NV241 (Rubicon) transfer cases.This new feature is only found on the latest version of the ProCal Module (part number 30406007AG). As of 2/18, all ProCal Modules being shipped from AEV are the latest version and include this function.
The flashcal does the same thing but that wasn't really the question. He's asking if it will still allow a second gear start in four low. I've never actually checked that that's true, and I don't own a Rubi to check it out. It seems like it defeats the purpose of having the 4:1 in there though, most people would never think to change to 1st manually.
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Old 01-06-2016, 10:35 AM
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The flashcal does the same thing but that wasn't really the question.
Yeah, I agree. The quote wasn't directed at his original question, I just thought it was interesting that AEV hints that by swiping the TC there is a possibility of inducing some type of "limp mode".

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It seems like it defeats the purpose of having the 4:1 in there though, most people would never think to change to 1st manually.
I agree. I never new about this feature before this thread. I think the "start in 2nd" is Jeep's way of addressing an issue I brought up in a previous post where I question if a very high crawl ratio drivetrain combined with an automatic transmission gets wonky to drive. I can imagine that 2nd gear in an auto with a 4:1 TC might be useful more often than 1st for all but the steepest, grippiest crawls, then 1st gear is there when you need it. Seems interesting that Jeep went thru the work of including the feature. They must have been addressing something they didn't like when it starts in 1st.

I don't have experience with automatics in an off-roader, which is why this is an interesting topic to me.
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Old 01-06-2016, 10:57 AM
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However, I think because of the canbus system, those switches will render useless to an after market locker.
That's an interesting point. I never thought about the lockers being part of the canbus system. From what I understand the computer disables/adjusts the ESP/traction control/ABS systems when the jeep is in 4-low? I'm assuming this has to do with the fact that if you engage the lockers there is no way to apply the breaks to individual wheels as traction control might want to do. If you reprogram the computer to allow the lockers to operate in 4-high, do think the computer adjusts the ESP/traction control/ABS systems to operate the same as when it's in 4-low?

How is all of this affected if you have aftermarket lockers where the Jeep has no way of knowing if the lockers are engaged?

I was hoping that by utilizing the Mopar Dana 60 axle package with elockers I'd be retaining all the feedback loops and systems that the Rubicon has with the stock axles. I assumed all the infrastructure was there even on a sport, it just had to be tapped into. Perhaps I have to start with a Rubicon to make that work.

I might move this to a new thread. We are off the path of transfer case swaps with this but I'd love to know.
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Old 01-06-2016, 12:54 PM   #23
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Since you have deep pockets have you considered an Atlas transfer case instead of the stock Rubicon case? Go with the 4.3:1 or 5:1 low range.
This is what I did. Love the twin sticks and the 4.3:1
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Old 01-06-2016, 01:08 PM   #24
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If you wouldn't mind sharing, how much did you pay for that transfer case? I think that new from Mopar they are around $2,200 and the Atlas is north of $2,800 if memory serves me right. For an ultra-low milage TC, if you beat those prices I think you did well.

I spend $1000 shipped for my TC.
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Old 04-24-2018, 04:35 PM   #25
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Stumbled upon this thread while looking to do a Sahara to Rubicon swap

I found new t-cases here
2016 Jeep Wrangler replacement Case Np241 in stock.
And I know that there are some out there that will buy used because they are cheaper but I didn't have such luck..... well from ebay anyways.... but still I hope this link helps out for those wanting to buy new and not wanting to get bent over the wood pile at the dealership.
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Old 04-24-2018, 10:14 PM   #26
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Buddy I wheel with did something similar to you. Bought a sport, immediately swapped the mopar 60s with 5.38 gears. He is still running the sport 2.72:1 transfer case and I it really hasn't been an issue.

What size tires are you thinking? you mentioned 4.88 gears, that seems pretty a little high, many folks run 4.88s with 35s. If you are on 60s I assume you are looking at 37s-40s when it comes to tires. I think you'd be better off with 5.38s...

something to think about.
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Old 04-25-2018, 11:23 AM   #27
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The rubicon switch board is in a difficult to reach spot anyway. Pillar mounted FTW
Or just get the Rough Country MLC-6 switch panel and use two of those to operate it. 199.00 and you will have 4 extra switches for lights etc...
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Old 04-25-2018, 02:53 PM   #28
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From what I understand the computer disables/adjusts the ESP/traction control/ABS systems when the jeep is in 4-low? I'm assuming this has to do with the fact that if you engage the lockers there is no way to apply the breaks to individual wheels as traction control might want to do. If you reprogram the computer to allow the lockers to operate in 4-high, do think the computer adjusts the ESP/traction control/ABS systems to operate the same as when it's in 4-low?

How is all of this affected if you have aftermarket lockers where the Jeep has no way of knowing if the lockers are engaged?
This occurs in all the JK's, not just the rubicon. My sport disables all of tc functions in 4 low. I also installed a manual switch to completely disable it whenever I want. It gets really wonky if you don't in higher speed runs in loose stuff in 4 hi too. Nice to be able to kill it. There is a factory switch to disable most TC functions but it doesn't do it all. There is a funky steering wheel dance you can do as well, but a simple little rocker switch does it quickly and easily.

as far as aftermarket lockers, i have never had mine on (eatons) when I was in anything but 4 lo so can't really answer that question. I guess if the TC functions are turned off it really doesn't matter...at least in my case.

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