2004 Rubicon Transfer Case Rebuild Kit

[Intimnasc]

So when I had the transmission out yesterday putting in a new clutch I was messing with the transfer case and do.ethi g just sounds loose I side to me. The seals are leaking as there is fluid everywhere. What's the best recommended rebuild kit that includes a new chain? It's an 04 Rubicon so what is the NP241OR?

 

[macleanflood]

I'd contact JB conversions. No kit listed on their website but I'm sure they have something.

https://www.jbconversions.com/index2.php?pc=7

If you call them remind them to update the copyright date on their website from 2023 to 2026.

-Mac

 

[Intimnasc]

Reached out to this place a couple of times let's see how they do this week. They lost them for the 241 Ford and Chevy but not the 241OR for the jeep. Hoping they call me back tomorrow and clarify. Also what do you guys think of the chain? I see advertisements for a side chain and a stock chain is it worth me upgrading going 4 wheeling 6 or 8 times a year? I'm thinking stock would be fine for me unless it is a severely poor design.

 

[macleanflood]

I've used the hell out of my stock chain and zero issues.

-Mac

 

[Mike_H]

Few years ago, I bought all my stuff from JB conversions. Did the stock chain as well. Little bit more expensive, but I trusted them WAY more than the other "kits" I found and it wasn't a terrible amount of money anyway...300 bucks or so?

There are some special'ish tools you'll need. Lots of snap rings, and there are the kind in there that don't have the little holes for "normal" snap ring pliers

Couple other notes:

DO NOT LOSE THE ROTOR OR DRIVE PIN IN THE SPEEDO HOUSING. They are unobtainium at this point.

There isn't a replacement filter screen for the oil pick up, nor can you rebuild the oil pump. Be careful with that and make sure you don't take the pump apart. Its in the back half, I believe, driven off the rear axle output. Follow the service manual.

 

[Intimnasc]

Thanks guys so I called him and he said the reason he doesn't list one for the Rubicon is apparently there were a lot of changes to the Jeep 241 transfer case between models and years. We talked on the phone a bit (he gave me his personal cell to call) and he said he could put a kit together with a new chain for 400 bucks. Seemed like he knew his shit and was very easy to talk to. Thank you guys. Ill order my hit when I get back from Finland in March since I wont have time to do the work before then anyways. I'm traveling 3 of the next 5 weeks starting today headed to LA.

 

[Intimnasc]

I'd contact JB conversions. No kit listed on their website but I'm sure they have something.

https://www.jbconversions.com/index2.php?pc=7

If you call them remind them to update the copyright date on their website from 2023 to 2026.

-Mac

Few years ago, I bought all my stuff from JB conversions. Did the stock chain as well. Little bit more expensive, but I trusted them WAY more than the other "kits" I found and it wasn't a terrible amount of money anyway...300 bucks or so?

There are some special'ish tools you'll need. Lots of snap rings, and there are the kind in there that don't have the little holes for "normal" snap ring pliers

Couple other notes:

DO NOT LOSE THE ROTOR OR DRIVE PIN IN THE SPEEDO HOUSING. They are unobtainium at this point.

There isn't a replacement filter screen for the oil pick up, nor can you rebuild the oil pump. Be careful with that and make sure you don't take the pump apart. Its in the back half, I believe, driven off the rear axle output. Follow the service manual.

Been calling and calling and cant get an answer or a returned call, are they still in business? Talked to him back in February and now that I am ready to order as quiet as a fart in the wind. hahahah

 

[Mike_H]

Been calling and calling and cant get an answer or a returned call, are they still in business? Talked to him back in February and now that I am ready to order as quiet as a fart in the wind. hahahah

No idea. I did mine probably three years ago now. Sorry I can't help more.

 

[mrblaine]

Few years ago, I bought all my stuff from JB conversions. Did the stock chain as well. Little bit more expensive, but I trusted them WAY more than the other "kits" I found and it wasn't a terrible amount of money anyway...300 bucks or so?

There are some special'ish tools you'll need. Lots of snap rings, and there are the kind in there that don't have the little holes for "normal" snap ring pliers

Couple other notes:

DO NOT LOSE THE ROTOR OR DRIVE PIN IN THE SPEEDO HOUSING. They are unobtainium at this point.

There isn't a replacement filter screen for the oil pick up, nor can you rebuild the oil pump. Be careful with that and make sure you don't take the pump apart. Its in the back half, I believe, driven off the rear axle output. Follow the service manual.

Before the definitions got so polluted with the extra wide results for search terms, they were called "lock ring" pliers. Now I have no idea what you would find them as. https://www.jbtools.com/wilde-tool-...l0Y8oHNXuI_DW6HY787_wQpDnDpypflhoC1BIQAvD_BwE

 

[Intimnasc]

So there is a kit on Extreme Terrain Linky linky but it says NP241D and when I look that up it says for Dodge. Do any of you have places you trust or can the one at Extreme Terrain work?

 

[Longwhitejeep]

All state gear has the bearing kit. Pretty sure that is the one I ordered. Thread from the how to section has the link.

They have a chain for it too if you need it.

https://wranglertjforum.com/threads/how-to-rebuild-241-or-241or-transfer-case.44680/
Check your rear output shaft retainer while you’re in there. Mine was an early case and didn’t have that drain back galley like the later versions.
https://wranglertjforum.com/threads...ransfer-case-on-tj-rubicon-models.9314/page-2

 

[Intimnasc]

Do any of you know what year models had the drain back and which ones were recalled? Or were all of them recalled?

 

[Longwhitejeep]

Do any of you know what year models had the drain back and which ones were recalled? Or were all of them recalled?

It’s in the link I sent