Transfer Case Refresh

[Molochnik]

I promise that I have indeed tried searching for something like this using varying search terms.
I've got a 2002 TJ X with 205,000 miles on it. Everything appears to be working fine, but I don't really know what a new TJ feels like; we bought it in 2019.

I have a 3.5" lift kit on order and I intend to pull the transfer case out to install an SYE. While it's on the bench, it would seem prudent to freshen things up in there, especially considering it's got >200,000 miles on it and we intend to do some pretty remote off-roading with it.

Are there any items in there that have shown themselves to have a finite life span? Weak points with stock part selection? A situation like "it's not IF it will break, it's WHEN it will break".

I plan to renew the chain. Presuming it's got a MOPAR chain in there, is another one going to be good enough? Is there anything better than MOPAR out there as for other parts?

 

[macleanflood]

I did a SYE on mine at 230k and didn't replace anything. Everything looked tight and right.

From a troubleshooting perspective IMHO keep it simple.

The oil pump is the hard part... getting it seated correctly going back together. Practice putting the case together 2-3 times before putting on RTV.

-Mac

 

[Molochnik]

I did a SYE on mine at 230k and didn't replace anything. Everything looked tight and right.

From a troubleshooting perspective IMHO keep it simple.

The oil pump is the hard part... getting it seated correctly going back together. Practice putting the case together 2-3 times before putting on RTV.

View attachment 556342

-Mac

Thanks for the input. I'm just trying to make sure there isn't some tribal knowledge out there that "everyone assumes everyone knows"

"Practice putting the case together 2-3 times before putting on RTV" Ha Ha! Good idea. Wiping off half cured sealant sucks; DAMHIK!

 

[OldBuzzard]

You'll need good lock ring pliers.
And a 1-1/8" socket for the yoke nuts.

If you remove the mode ring, be sure to put it back in the right way.

 

[Molochnik]

You'll need good lock ring pliers.
And a 1-1/8" socket for the yoke nuts.

If you remove the mode ring, be sure to put it back in the right way.

Yeah, I've watched a couple of videos and they all seem to be using snap ring pliers on the order of a foot long. The description of these shows 11". I may have to pick some up. My plier selection is of the "normal" 6" type. Thanks for the confirmation. Been working on motorcycles and airplanes too long

 

[OldBuzzard]

The tips are spreaders only, which is what you need.

 

[Molochnik]

Aha, good to know!
I don’t have any like that…yet

 

[Molochnik]

My lift kit just got delivered. I guess I need to get going on ordering the SYE kit