Transfer case issues

[Logan6464]

That shaft angle doesn't look terrible... What were you doing when it broke both times? Were you spinning and it hooked up, or jumping it and maxing the suspension? I can't see a reason why it would break twice in the same spot unless there are other factors.

It was driving up hills both times. Bout 45 mph and 2,000 rpm. Nothing crazy

 

[Logan6464]

The PO of our LJ put in a 1 inch engine mount lift after installing a 3.5” SL, to help with the driveline angle. Mind you , the LJ has already the advantage of a longer rear driveshaft
Just saying

After further evaluation I don’t think I have a 4 inch lift. Might be a 2.5 or 3. It was installed be prev owner.

 

[Gilaguy23]

If that pic you posed is how it sits normally it sure looks like you have almost no overlap on the T case stub to the DS yoke splines. It may be an illusion but it looks like the DS is at a couple degree angle from the T case like the splines are shot and the yoke is just hanging on by a thin margin sloppin around.

 

[Gollywomper]

If that pic you posed is how it sits normally it sure looks like you have almost no overlap on the T case stub to the DS yoke splines. It may be an illusion but it looks like the DS is at a couple degree angle from the T case like the splines are shot and the yoke is just hanging on by a thin margin sloppin around.

If this is the case try moving your drive shaft around looking for slop at the slip yoke end.

 

[Logan6464]

If this is the case try moving your drive shaft around looking for slop at the slip yoke end.

Seemed solid when I put it back together. Can’t rlly test that now tho

 

[Jezza]

It almost looks like the yolk is bottomed against the damper in the pic. Is there space between the damper and the yolk? It might break if the splines are bottomed out.

 

[Gollywomper]

It almost looks like the yolk is bottomed against the damper in the pic. Is there space between the damper and the yolk? It might break if the splines are bottomed out.

Looks like it. The way the splined portion is so shiny it looks like the drive line is for an older TJ with the internal slip/splines. Which would probably make it too long for the external setup, maybe.

 

[Logan6464]

Looks like it. The way the splined portion is so shiny it looks like the drive line is for an older TJ with the internal slip/splines. Which would probably make it too long for the external setup, maybe.

Shiny part was where the dust boot was. Didn’t have it on me when I installed it so I left it. I’m pretty sure

 

[Logan6464]

So I looked at the jeep more this morning. And the whole case is cracked. So what am I looking for for a new one? (2001 sahara 4.0L) can a t case from a 2.5 work? Is there any different t cases from different years? Is there some that do and don’t work?

 

[Gollywomper]

The 2.5 case and most all 4.0 cases have a different input shaft spline counts. They are easy enough to swap with your current case though.
However. If the case wasn’t cracked when you took it apart last time and it is now. You need to find out what is going on before you crack your replacement case. If you can find a case with a SYE already done you will be better off. Will be able to remove your tcase skid spacers. Of course this will require a new rear drive line to complete.

 

[Logan6464]

The 2.5 case and most all 4.0 cases have a different input shaft spline counts. They are easy enough to swap with your current case though.
However. If the case wasn’t cracked when you took it apart last time and it is now. You need to find out what is going on before you crack your replacement case. If you can find a case with a SYE already done you will be better off. Will be able to remove your tcase skid spacers. Of course this will require a new rear drive line to complete.

Yeah just gotta figure out what’s going on