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Discussion Starter #1
2002 TJ 4.0. 2.5" suspension lift no SYE & almost 200K miles. If you have seen my other post I recently discovered my rear track bar was not attached to the frame bracket. But I have been battling a driveline vibration. Here is what I have done in order. Replaced all U joints, balanced and rotated tires, balanced front and rear drive shafts. Vibration is still there. Today I removed the rear driveshaft and took it out on the highway. I had NO vibrations kick in at 50-55 and got my speed up to 65 and still no vibrations. My plan is on Mon to have the balancing of the rear driveshaft double checked. I am hoping that's the problem. But if it's not, where should I look next?

I did take a short video of the output shaft spinning. I think it's ok. ( dont think I can post it ) If there is a way let me know.
 

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Your problem appears to be with with the rear DS itself (balance, u-joints, slip shaft) or the angle at which the DS is working. You seem to be on the right track to diagnosing the problem.
 

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Discussion Starter #5
Got it to the shop. Drive shaft is perfect. However, the rear output shaft on the transfer case is bent. So now it's do I DIY the transfer case output shaft repair or swap it out the whole transfer case with a used one. I know a guy with one. About 111K on the jeep
 

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A new SYE would be much cheaper and easier IMO
 

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Discussion Starter #9
I don't have a SYE now. I have the standard OEM transfer case and out put shaft. I figure getting set up with the transfer case, sye, and driveshaft would be $$$.
 

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Discussion Starter #10
I only have a 2.5" suspension and the guys at the shop all agree no SYE is needed, my angle is good. So just need to figure out do I replace the output shaft and rebuild it or just swap it out with a used one
 

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you are correct, you can just replace the output shaft. what I, and assuming others, were saying is that if you're going that far, why not upgrade to a SYE. at 2.5" you are on the cusp
 

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Discussion Starter #12
I see. No just want to keep it the way it is. I am guessing the straight swap out with a used one would be the easiest....just a gamble on if I will have issues with it.
 

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I'd repair the transfer case you have. You'll learn something in the process and not have to worry about getting someone elses junk.
 

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Discussion Starter #14
Looking like I can just repair mine for about $225-$300 depending on which transfer kit I get ($100-190) plus about $100ish for the main shaft.
 

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Discussion Starter #15
Any suggestions on where to get a transfer case rebuild kits or main/outputshaft? I am shopping, but discovering I could have a 1" chain or 1.25" chain....and rumors say the only way to find out is to open it up.
 

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IF the transfer case in your Jeep is the original... then it will be a NP 231 J which always comes with a 1" chain unless someone has already upgraded the chain previously. The only other way the chain can be a 1.25" is if the transfer case is a NP 231 D from a Dodge Ram or similar truck.
 
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