[Angler1979]

Well as part of my build I had do do a slip yoke conversion so I decided to do a write up for fun there are a lot of good write ups on this subject but I figured it would be nice to have as much pictures out there as possible so here goes I used a terra flex Super short SYE kit. this a np231j out of a 1994 YJ
First remove your drive shafts, and skip plate.

You can do the conversion with the tcase in the jeep but its a lot easier to do it out of the jeep. I found a 9/16 ratchet wrench was the best tool to use to remove the 6 nuts that mate the tcase to the transmission, the shifter linkage also is 9/16ths, pull off the linkage, the nuts, ans the vacuum plug also remove the vent tube. once you have all this stuff disconnected remove the t-case. I used the bench press technique to remove it.

Once you have the t-case out of the jeep the first step is to remove the yoke for the front drive shaft, an impact would be the best tool for this but I am a redneck so I had to do it the hardest way possible I used a 24inch adjustable wrench to hold the yoke while I broke the nut free with a 2foot breaker bar.

I then cleaned the dried mud off the tcase so when i split the case halves it would not get inside the case.
Next step is to remove the factory output housing.

Next step is use lock ring pliers to remove the snap ring that holds the out put bearing in place on the factory out put shaft.

next remove the speedo drive gear assembly

next remove the bolts that mate the output housing to the transfer case and remove the housing itself
After the housing is removed remove the bolts that hold the two case halves together

there is one 12 point 10mm bolt and all the rest are 15 mm why they did this I don't know

once all the bolts are removed find the two machined slots to pry the case haves apart if you pry anywhere else you will bugger up the mating surfaces and the tcase will leak.

on both of the transfer cases I have built they pop open very easy
be careful not to drop the oil pump when you take the front case half off.

this is what it looks like when you take the case apart

 

[Angler1979]

next remove the output shaft, front output gear and shaft and chain all together there is a coil spring on the shift fork you will have to put back on before assembly.

lift the factory output shaft out of the drive chain remove the lock ring that holds the drive sprocket onto the factory output shaft and slide them off the factory shaft and on to the new shaft.

Both the t-cases I have done have been out of YJ's and there are t sets of bearings in the drive sprocket you have to remove or it wont fit on the new shaft.

A brass punch would be best to remove so you wont scare up the surface but I am a redneck so I used a screwdriver and hammer with two blocks of wood. I was careful and did not mess up the sprocket

once you drive the bearings out put all the drive gears on the new shaft and install the new snap ring install the front and rear output shafts, drive chain, and shift fork into the front case half reinstall coil spring on the shift fork.

I then took the extra min to clean the magnet and oil pick up screen

when this is done clean the case halves with a razor blade and some brake cleaner and apply a bead of RTV

put the case haves back together and put the bolts in and tork them down to 30ftlbs. I also put lock tight on the bolts for fun

This next step applies only to Super short shaft kits, you want to slide the speed sensor ring onto the output shaft

After the speed sensor ring is on install the new output housing with rtv just like you did the case halves.

then install the speed sensor

 

[Angler1979]

Last step is install the output yokes on the front and back

tork the nuts down to 180lbs per teraflex recommendations.

My Daughter wanted to help daddy build the transfer case but she only knows to use one tool

After you install the yokes reinstall the t-case into the jeep and measure for your drive shaft.

Tools needed
1 1/8th socket
15mm socket
10mm socket
flat screw driver
snap ring pliers
tork wrench
gasket scraper
9 1/6 ratchet wrench.
3/4 inch socket to remove skid plate.

would rate this 4 on scale of 1-10 difficulty
takes about 3 hours to do

Hope this helps someone

 

[amara8]

Outstanding post. keep this as a sticker.
iam going to remove the T-case, instead of trying to do this while still on the jeep.
Where is this oil pick up screen located?
What do you look for in that chain, how do you tell if it's worn. or too lose.
My 91 has a manuel speedomiter cabel, is their a kit for this change to speed sensor?

 

[Angler1979]

The oil pick up screen is located in the front case half when you take off the output housing the first thing you see is the oil pump. the screen it located over the magnet

The chain will have slack in it, inspect the chain to see if it has any broken links, if your chain is messed up you will see allkinds of fragments stuck to the magnet

Teraflex makes an adapter for the older speedo cables I think but I am not sure you will have to call them.

 

[Triple88a]

Here is a video also http://youtube.com/watch?v=_hGpjCAkOvk

 

[Felsengleiskette]

pimp. great post brother. i'll def. refer back to this when i do mine

 

[yj4x4]

hey im plannin on doin an sye conversion. where is the best place to get the parts to do it.

 

[yukondubs]

http://www.jbconversions.com/index.html :wavey:

Super-short kit that is about 3 inches shorter than normal SLE kits.

This company seems to be the best around, they have made inprovements to their kits that really expand on most i've researched.

Just broke rear driveshaft today, will be getting one soon.

http://www.4xshaft.com/index.html - Tom Woods Custom Drive Shafts. They sell a kit with the JB SLE kit and double cardan driveshaft I think I'll be getting. Sweet setup.

Has anyone used either one of these??????

 

[1BLKJP]

http://www.jbconversions.com/index.html :wavey:

Super-short kit that is about 3 inches shorter than normal SLE kits.

This company seems to be the best around, they have made inprovements to their kits that really expand on most i've researched.

Just broke rear driveshaft today, will be getting one soon.

http://www.4xshaft.com/index.html - Tom Woods Custom Drive Shafts. They sell a kit with the JB SLE kit and double cardan driveshaft I think I'll be getting. Sweet setup.

Has anyone used either one of these??????

I run the super short SYE and love it. It gives me like a 22 inch driveshaft or something to that affect. Only negative is in the speed sensor for most. You have to buy a programmer to adust the speed due to the tone ring replacing the speedo gear.

 

[fbtased2002]

Great post

the pics are great too. I but i do have have two questions.

1. How tough/necessary is it to adjust the pinion angle?
2. i would like to install a teralow 4 to 1 kit at the same time any idea if the two kits will work together?

 

[NAVYCHIEF]

where can i get a 1994 wrangler speed sensor drive? not the whole thing, just the internal speedo gear.

 

[Triple88a]

Chief, which speedo gear? the black one on here or the other one that connects to it inside the hole?

 

[Heff733]

haha just did my sye kit... was having problems here i had the stupid oil pump inside the case! i must have looked and the gears 30 times... when i would put the case together it would bind up the chain in 2 hi .... make SURE u install the pump to the pick up screen on the outside of the case before puting case back together... that dumb mistake made my onstall 5 hrs longer..haha good thing its not a daily driver!

 

[1BLKJP]

haha just did my sye kit... was having problems here i had the stupid oil pump inside the case! i must have looked and the gears 30 times... when i would put the case together it would bind up the chain in 2 hi .... make SURE u install the pump to the pick up screen on the outside of the case before puting case back together... that dumb mistake made my onstall 5 hrs longer..haha good thing its not a daily driver!

Don't worry first time I did one a buddy took it apart and I put it back together and did the same thing.

 

[tebbsjeep]

Hey I just installed this kit on my tcase, but I can't get the supplied bolts to slide into the yoke. Did you have this problem?

 

[05wrangler]

nice write up man!

 

[Dkipz]

I know this is a 10 year old thread but is there any chance the pictures from the original posting can be updated to appear again? I’m going to be doing an SYE kit on my 95 YJ soon and wanted to have some pictures to look at for comparison. The YouTube videos I’ve seen are usually pretty grainy. Any info is appreciated - thanks in advance!
-Dan