2009 Winter/Spring Projects - T-case, Rear Axle, Driveshafts... blah blah [Archive]

TheOtherSide

02-03-2009, 08:51 PM

I renamed the title to this thread as it's turning into a few extra things on the Jeep.... so now it's a bit more accurate as to the content of this thread!

So I'm ready to begin... it's a "project" as there are a few things getting done at the same time.

Taking out the 249 AWD t-case...

Fitting the new 231 4wd t-case and possibly swapping the input shafts between the 2 cases if needed. Once the input shaft thing is rectified, I'll be installing the SYE (which I already have). Of course I need to swap over the 231 linkage and shifter etc... which I already have.

Then I need to lift the rear with my 1" taller Rubicon Express springs (which lifted it 2" on the test fit.... but it'll settle.

THEN... I'd need to get a new rear driveshaft made!!

Fun fun... it's about time!!

Jeremy

02-04-2009, 10:05 AM

Sweet!!!!

When dose this project start?

Jeremy

TheOtherSide

02-04-2009, 03:25 PM

Sweet!!!!

When dose this project start?

Jeremy

Maybe tonight!

JaredS

02-04-2009, 06:38 PM

Can't you just use an XJ front drive shaft?? That's what I got in my XJ....don't know how different the dimensions are for the rear ZJ

TheOtherSide

02-04-2009, 08:25 PM

Can't you just use an XJ front drive shaft?? That's what I got in my XJ....don't know how different the dimensions are for the rear ZJ

ZJ is much longer... no worky.... maybe 3-4" longer

TheOtherSide

02-04-2009, 10:33 PM

Okay... so it didn't start tonight... I spent some time organizing and tossing stuff out. (mainly VW stuff).... now I have some space.

I think I'll pull the t-case out on a weekend daytime for a bit more light... then I can build and modify the t-case inside the garage with more light and a heater too!

-Scheff-

02-05-2009, 03:37 PM

Hey K...if you are doing a Saturday morning R and R type of thing I'd like to hang out, I need to start planning my T-case and front drive shaft swap, might as well tag along...let me know.

Jeremy

02-06-2009, 02:14 PM

Sounds like a fairly strait forward swap, is there any fab work needed or is it all bolt in?

TheOtherSide

02-06-2009, 04:13 PM

All bolt in... may need to swap input shafts. Also have all the new linkage from the ZJ with the 231 to put in. Easy stuff overall.

TheOtherSide

02-07-2009, 12:47 PM

Update:

Got the t-case out... fun having some seized and stripped u-joint bolts...

Thanks to Nathan for assisting in lifting the t-case out.

Checked the input shaft... I'll have to be changing it. The one from my V8 is quite a bit longer... so I'll pull it and swap it into the new t-case.

Now... thinking of putting the Tera 2-Lo kit in... for the reason that when we wheel... I'm typically in Lo gear due to my gear ratios. Rarely in Hi gear... so if I put the t-case in as is... I'll be in lo-lock all the time... and if I have the 2-Lo option... that will help out for a while until I get my axles re-geared.

Opinions? (not doing axles until next winter or the winter after... I want to gear them, locker them and install them all at once... $$$$). So 2-Lo is a cheap gear ratio helper for me to not always be in Lo-lock.

:headspin:

TheOtherSide

02-07-2009, 12:55 PM

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=140009887355&fromMakeTrack=true&ssPageName=VIP:Watchlink:middle:us#ebayphotohostin g

$50 cheaper than the Tera website

Hmmm....

BigWhiteFord

02-07-2009, 02:13 PM

I love having 2-Lo. Mine is a sort of ghetto 2-lo of course, as I just put the transfer case in Lo-range and leave my front hubs unlocked. I found with my XJ that I was using 4-Lo all the time, to get the deeper gearing for climbing or descending hills, even though I didn't need/want to be in 4wd.

Have you thought about converting to manual hubs? That way if you threw in a locker in the front, it wouldn't suffer unnecessary wear and tear from road use.

I don't even know if you can do manual hubs on the D30, but I thought I'd throw the idea out there...

TheOtherSide

02-07-2009, 02:19 PM

I've been thinking about maybe next winter sourcing out Grand Wagoneer front and rear D44's. They have manual hubs and are the correct width.

But for now, def thinking about the Tera 2wd low...

Sero

02-07-2009, 02:55 PM

Sero

02-07-2009, 06:50 PM

I've been thinking about maybe next winter sourcing out Grand Wagoneer front and rear D44's. They have manual hubs and are the correct width.

But for now, def thinking about the Tera 2wd low...

Some info on D44, I didn't realize the front waggy was a low pinion...not much use swapping that in especially if your doing a 2 low kit in your t-case.

http://www.naxja.org/forum/showthread.php?t=983945

TheOtherSide

02-08-2009, 09:40 AM

Just bought the Tera 2wd Low....

http://www.teraflex.biz/products/media/catalog/product/cache/2/image/5e06319eda06f020e43594a9c230972d/f/i/file_18_5.jpg
:headspin:

Jeremy

02-08-2009, 12:33 PM

:O Ballin!!!:pipe:

TheOtherSide

02-09-2009, 11:06 PM

Secured my replacement rear Bilstein Shocks.... so now I just have to build up the t-case when the parts arrive, put in the rear springs and get the rear driveshaft built.

Fun fun!!!

BigWhiteFord

02-10-2009, 08:26 AM

$1000 for manual hubs for a D30 ? Are they mad? Who in there right mind would spend that!

Jeremy

02-10-2009, 09:02 AM

Kelly the onlt way to go with axles is a D60 in the front and a 14bolt in the rear. That way you can have axles that can take the 37" boggers!

*Sawzall sold seperait*

Jeremy

BigWhiteFord

02-10-2009, 10:08 AM

Kelly the onlt way to go with axles is a D60 in the front and a 14bolt in the rear. That way you can have axles that can take the 37" boggers!

*Sawzall sold seperait*

Jeremy

Why stop at 37" when Interco makes a street legal 49" ?? :party:

TheOtherSide

02-10-2009, 10:32 AM

Yeah, I'd never put manual hubs on a D30.

However... a D60 & 14 Bolt is always tempting... but then I have to get long arms.... and big tires... then it get to start breaking driveshafts & t-cases etc. It all just keeps moving to the weakest link...

:crazy:

Sero

02-10-2009, 10:40 AM

$1000 for manual hubs for a D30 ? Are they mad? Who in there right mind would spend that!
No kidding...I've never seen a set out there...

Sero

02-10-2009, 10:42 AM

*Sawzall sold seperait*

Jeremy

We don't need no stinkin sawzall...have something much better!! :D

Besides I have a sawzall already

Sero

02-10-2009, 10:44 AM

TheOtherSide

02-10-2009, 10:59 AM

Kelly let me know when your going to start stripping down the case's.. I'd like to help. If your doing and evening there's a better chance.

You pick up a seal kit for it? or are you going to wait untill you see if you need a rebuild kit?

Likely tearing down the 249 thursday evening and want the input shaft out of it then. May start tearing down the 231.

I think $100 USD is a bit steep for just seals and a few bearings... I may just get a couple of seals from the dealer... and leave the bearings unless they look/feel bad.

Sero

02-10-2009, 11:36 AM

Likely tearing down the 249 thursday evening and want the input shaft out of it then. May start tearing down the 231.

I think $100 USD is a bit steep for just seals and a few bearings... I may just get a couple of seals from the dealer... and leave the bearings unless they look/feel bad.

I saw a seal kit for it somewhere for 20 or 30 USD.

TheOtherSide

02-12-2009, 06:04 PM

Look what arrived today:

http://www.overlandcanada.com/net/tera.jpg

:crazy:

TheOtherSide

02-12-2009, 10:49 PM

Got my 249 case all apart and got the input shaft out....

Began taking apart the 231.... good progress tonight.

TheOtherSide

02-15-2009, 05:41 PM

Took the new-to-me 231 apart the other day.... excellent condition inside. Everything is almost perfect... chain is tight etc. Just need a replacement input shaft as the one out of my 249 t-case is not up to my standards.

Went to Pick a part today as their records show they had a 95 Grand Cherokee... with the correct t-case I needed for the input shaft I need for my swap... only thing is that 1995 is the transition year, so it could have early or late style gear... and I need the early. So Nathan and I pulled the t-case and took it apart... wrong one for me. Total waste of time... and a bit frustrated, but at least I tried.

Back to square one....

:mad2:

TheOtherSide

02-17-2009, 08:47 PM

So finally with stressing everyday and doing over and over searching on the net... I found 3 brand new options varying from $290 cdn, to $85 usd... and finally ordered the new $85 usd unit from Morris 4x4 Center. I asked Morris, and their supplier is Novak Conversions (who was asking $165 usd and is a very reputable t-case supplier). So anyhow... the new replacement input shaft is finally ordered!!!

I was also able to order the specific seals for my case to complete the rebuild.... so hopefully all the parts will arrive by this weekend and I'll likely get the parts from my US postal box early next week. I like one stop shopping!

So.... the t-case swap is back on!!

:headspin:

TheOtherSide

02-17-2009, 08:53 PM

OH.... forgot to put in a plug for Morris 4x4 Center... here's the link:

http://www.jeep4x4center.com/

TheOtherSide

02-19-2009, 09:26 PM

So yeah.... what seems to be too good to be true, usually is. Morris came up short... can't get the shafts for $85... and they seem not to be able to purchase from Novak anymore. So I ended up buying the shaft direct from Novak for $165. Oh well... what can you do.

Oh, as a side note... Morris has pretty crazy expensive shipping rates... keep that in mind if you end up buying from them.

:rant:

TheOtherSide

02-26-2009, 07:03 PM

We went to Blaine to pick up all my parts today....

Got my brand spankin new input shaft!! ($$$) and the seals. Nice quality seals from Morris 4x4 Center. So now I have to find time and get that thing back together and into the Jeep so I can get the rear driveshaft built... and contemplate if I want to get a new front one built at the same time.

Tom Woods wants $299 each shaft USD. (6" max slip yoke avail)

Pats Driveline wants $400 for the front and $425 for the rear CDN. (4" max slip yoke avail)

Quite likely going to do Tom Woods as I like the 6" slip yoke considering my control arms can put quite an arc on the axles when moving in and out... won't hurt to do that to make sure I don't get a shaft popping apart.

Wee.... time to get that thing going!!!

Next project.... Flowmaster 40!

:headspin:

TheOtherSide

03-06-2009, 09:59 PM

Yeah okay.... the crappy Magnaflow system on my daily driver has driven me crazy enough that I'm not switching to a flowmaster 40 on my trail Jeep.... no way.

Anyhow... I'll be starting to put the t-case together tomorrow... can't wait!!

TheOtherSide

03-08-2009, 08:36 PM

T-case is all together now. Has the Tera 2Low kit and the Slip Yoke Eliminator in it... will post up some pics later with differences in shafts and parts for the 2low kit etc.

Hope to put it into the Jeep this week!!

TheOtherSide

03-11-2009, 07:29 AM

Alright... here are some photos:

http://www.overlandcanada.com/net/tcase/001.jpg
Top is the stock output shaft.... bottom is the short and beefier Slip Yoke Eliminator kit shaft...

http://www.overlandcanada.com/net/tcase/002.jpg
On the left you have the stock selector arm... on the right the Tera 2Low selector arm.

http://www.overlandcanada.com/net/tcase/003.jpg
On the left is the stock low range fork.... on the right is the Tera 2Low low range fork...

http://www.overlandcanada.com/net/tcase/004.jpg
Just starting to put it together. Got the input shaft and planetary gear set in place.

http://www.overlandcanada.com/net/tcase/005.jpg
A few more things installed... front output shaft is in (on the left), rear output shaft (on the right) and connected by the 4wd chain.

http://www.overlandcanada.com/net/tcase/006.jpg
Mostly finished. Boy the case looks dirty on photos. I solvent tanked the case and it's super clean compared to how I got it. That's the brand new $220 cdn input shaft you see on the left side... and the front output shaft on the right side waiting for the yoke to be installed.

http://www.overlandcanada.com/net/tcase/007.jpg
And all done... the shiny housing is the new tail housing for the slip yoke eliminator kit. That that shiny yoke is the rear yoke.

Just have to sort out my shift indicator switch... it's too long for the Tera selector... and it jams the selector... so I'm most likely going to just put a plug in it... or find a TJ indicator switch which apparently works. Likely going to plug it... I know what gear I'm in on the t-case... don't need a light telling me "Low" or not. The ZJ limited only shows "Low" in the display.. nothing else... so I have a feeling I'll know when I'm in low!

TheOtherSide

03-12-2009, 07:02 PM

T-case is in....

Put my front driveshaft in the back to test it out... a bit too short but it worked to move it around. Chirps the rear tires with little effort in 2low... :D

Anyhow... need to move the fuel lines a little bit, they're too close to the speedo sender and will start rubbing through something
http://www.overlandcanada.com/net/tcase/008.jpg

Put the driveshaft in the rear so I could see the status of the pinion angle.. needs to come up a bit (hard to see in the photo)...
http://www.overlandcanada.com/net/tcase/009.jpg

So it's coming along and I'm excited to see how it does on the trail!!

Next week.... ordering a rear driveshaft and getting my front one fixed up (the slip joint is partially siezed I found out... no good).

JaredS

03-12-2009, 07:40 PM

Looks good man! The 2LO will be very useful I think! I need one....!

Jeremy

03-18-2009, 09:06 AM

2 Low and a locker will get you almost anywere, looks great Kelly!!

Gona be ready for Snowcamp 09?

Jeremy

*not to self need a winch*

TheOtherSide

03-18-2009, 11:21 AM

Jeremy

03-18-2009, 11:48 PM

Get the drive shaft?

TheOtherSide

03-19-2009, 08:27 AM

Yup... got both done.

AxelR

03-19-2009, 08:53 AM

It's all Greek to me (being a Toyota guy) but sounds good nonetheless. Where are the pics?

TheOtherSide

03-19-2009, 05:07 PM

Pics on page 4 of this thread. Had a temp driveshaft in it at the time.

Hope to get the shafts put in tonight.. and then replace the brakes on the new axle... oil it up and we're rollin'

AxelR

03-19-2009, 05:38 PM

TheOtherSide

03-19-2009, 06:26 PM

Ah, I missed that somehow. Looks good. Taking apart tcases is so much fun. Those pics make me want to do my duals all over again. When I took my chain drive case out I took it apart just for ****s and giggles.

So what kind of crawl ratio is that setup going to get you?

Hahaha... did you say crawl ratio? Seems Jeeps aren't so into crawl ratios apparently. I have the stock t-case ratio... 2.72/1. Costs big $$ to go into different ratios or more speeds. Would be nice to... but I guess I just have to lean on my 300 lb/ft of V8 torque to get me through stuff!

:headspin:

AxelR

03-19-2009, 07:07 PM

Oh I thought it had lower gearing as well. Forgive my ignorance but why are you swapping tcases then. I'm going to guess the new case gives you 2wd since Grands were full time 4wd? Doesn't Jeep have a 4:1 that'll go in there or is that the big money you were mentioning?

TheOtherSide

03-19-2009, 08:14 PM

My Jeep had a 249 case which is all wheel drive all the time. Only have high and low options... and power is distributed by a viscous coupling. Not so good for 4 wheeling and street... just street. The 249 also has a slip yoke on the back of the t-case and cannot get any slip yoke eliminator kits for them. The 242 has 2wd, 4wd and awd options... and is a good case... but is as large as the 249 and has a couple of options for slip yoke elminators, but the most common version is the "hack and tap" version where hack off a portion of the output shaft, then drill and tap it to put together a SYE. Not a huge fan of that one. The 231 is a 2wd and 4wd only case.... and has lots of aftermarket support... and it's also the smallest case is size due to its simplicity. I chose this one... put the SYE on it and the 2low kit also.

As for crawl ratios... there is a 241 from the Jeep Rubicon that has a 4:1 ratio, but they are pretty pricey to find used. You can get a 4:1 kit for the 231 and they're $1200 usd and you still have to get SYE's for them.

If I was going to dump big $$ into a case, I'd go for an Atlas case which has multiple speeds with some nice crawl ratios. I guess since I've only ever had high and low and only had Jeeps... guess I don't really see the benefits to going to crazy crawl ratios with the terrain we have.... BUT... like I said, I haven't been in a truck with a crazy ratio so I can't appreciate it.... maybe it's time to have a ride in your truck!! :D

So long and short of it is... with my t-case swap... I will now have my front and rear diffs locked to have equal power in 4wd... and also a 2 low option and also slip yoke elminiator for my higher driveline angle... all of which I could not have with my big fat awd 249.

Looking forward to playing with a comletely different t-case and should also see big differences in climbing with a locked case instead of a viscous coupling.

Oh geez... I just noticed I typed a short story... hahahaa....:eek:

AxelR

03-19-2009, 08:55 PM

Ok got it. Cool I learned something new today. I guess us Toyota guys have it pretty easy with those older gear drive cases.

I have to admit the super duper low is REALLY nice. It just makes difficult manuevers so much more controlled and less scary. Then again maybe if I was a better driver I wouldn't need it. HaHa. Looking forward to checking out your Jeep. I always liked the Grands. Not enough to give up my Toyota but I always liked the way they looked. I drove a friends stock one too and was impressed with it.

I have to admit if something ever happened to my truck and I had to get a new one I would seriously consider one of the new JK's. Can't believe I just admitted that.

Sero

03-20-2009, 02:22 PM

Working hard...

driveshafts will be done today.... just picked up the D44a that's going in hopefully tonight if I can get Jas or Nathan to gimme some muscle.

(fluked on a D44a from a 97 Grand Cherokee from pick-a-part with the right gears and factory limited slip... so it's the temp rear axle until the D44 is built)

Another D44? Did it come with brakes on it? If so that would be cool then you have spare beake parts that you could swap or even sell to an XJ guy.

You could see if you can get a few extra clutch's for that limited slip to tigten it up... or weld the gears... :D

Just don't be tempted to leave that thing in there when you have the real deal sitting in your garage.

TheOtherSide

03-20-2009, 04:24 PM

I pulled it out 100% complete. Brakes were done... so I'm putting new e-brake shoes, rotors and pads also.

My plan is to take the complete discs from the bad DD axle and use them for the XJ D44 axle...

Yeah... maybe I should weld it all up!! hahaa....

Sero

03-22-2009, 08:46 AM

Something for the jeep guys may be in the future:
http://advanceadapters.com/product/4341/42R241JK-Rubi-Crawler-Jeep-JK%27s-w/-NP241.html

Sero

03-22-2009, 09:04 AM

My plan is to take the complete discs from the bad DD axle and use them for the XJ D44 axle.......

Is the D44A a c-clip axle? If it isn't it may be better to swap the brakes from the d44a to the real d44.

Yeah... maybe I should weld it all up!! hahaa....

DO IT!!!!

:party:

TheOtherSide

03-22-2009, 09:23 AM

D44a is a c-clip axle...

and I just glued on the diff cover... it'll stay like that. However... it would be a good idea to weld it all up and see what it would be like to be spooled so I can decide if I wanna go spool or locker with the D44 build...

Sero

03-22-2009, 10:42 AM

So with your the d35 you just took out we have 3 sets of shafts... don't need those now. Sell em for $25 a set?

TheOtherSide

03-23-2009, 02:53 PM

Yeah, we can unload a couple of sets of shafts.... I'm gonna keep one set for sure as the DD has a D35. Not that it'll need them, but it doesn't hurt to keep one set.

So I got the rear e-brake shoes done... and new pads & rotors also. Now I need to play with the pinion angle on the D44a... and a few little adjustments and it may be mobile.

For some reason the front driveshaft was made too long. I remeasured and got the same measurement... so it looks like it'll have to go back to get shortened.... hope I don't have to put out $$ for this shortening.

Anyhow I'm just itching to get this thing mobile... so I can test out the rear axle and t-case etc before a trip. Don't want to make it the first time driving it when heading out on a trip!

TheOtherSide

04-23-2009, 04:43 PM

I forgot to put in a little bit of feedback on the t-case and 2low kit.

GREAT!

I really enjoyed being in 2low and there was one time when I was in the ugly mud where the rear wheels started to dig in and spin... and fired it into 4low and came right out without anyone even catching on that I was getting into an ugly spot. Then when I was mobile again and on good ground, on the fly back into 2low. Very nice. I like it!!!

I have a good vibration from the rear shaft when the truck is empty... and it goes away when loaded right up. So I'll have a little pinion angle to adjust and I'll be good.

So 2 thumbs up to the Tera 2low kit for the NP231 t-case!!

Also... the rear axle with the limited slip did well... was happy how that worked too!

Overall... happy with all the mods for this year!!