Need transmission/tc help

**gunshw301** · 03-10-2012, 08:52 PM

Okay so I finally got my transfer case dropped tonight. I have the ax5 231 combo. Here are a few questions I am hoping some of you can guide me on.

1. When I was removing the transmission mount bolts. I snapped the smaller of the three. It's separate from what I would call the trans mount. Kinda looks like a body mount set up. I need to replace this, but can't find it because I am not sure what it's called. I think I just want to replace it all, bolt and rubber mounts. It also seemed very loose and when in 4wd the tc shift knob would jolt around. Is this the cause?

2. When I separated the transfer case from the transmission the transmission started to leak. Is this normal? It was semi dropped for access, but is there a seal I should replace? I don't remember reading about having to watch for oil loss.

3. Thinking about getting a cable operated transfer case linkage. Anyone have one, is it worth it?

4. My new transfer case has 2wd low. How far back do I need to cut the tunnel cover to allow for this? The case is used but new to me and not really sure about it. If I use the cable shifter do I need to cut?

I know it's a lot, but thanks for the help. Hopefully I can get this think back on the road again soon now that the weather is nice.

moonshinefuel · 03-10-2012, 10:21 PM

#1, is your torque arm bushing/bolt. It's supposed to have some play. If your transmission/transfer case shifting assembly is moving around too much, maybe you need a new transmission mount. Perhaps a polyurathane one, or at least an oem replacement.

moonshinefuel · 03-10-2012, 10:27 PM

#2 maybe, maybe not normal. There is a seal on the back of ax5 transmission, It's real easy to pop off there and replace with a new one. However! If it was leaking due to the angle and simply spilling out, then I see no problem.

moonshinefuel · 03-10-2012, 10:33 PM

#4, what transfer case are you installing, what year, and what case?

**gunshw301** · 03-11-2012, 07:51 AM

Thank you for the responses. Yes the transmission was tilted so that's good that its normal than. The tc is a 231 with Teralow and 2wd low installed. I need to open both cases and swap out input shafts for sure. But when I bought it the guy said something about cutting the tunnel. I was originally going to pull it out and resell it, but now I think I will just leave it in.

jeepnbrett · 03-11-2012, 08:23 AM

I just installed the 2lo kit and didn't need to do any trimming.

moonshinefuel · 03-11-2012, 09:07 AM

Quote:

Originally Posted by gunshw301

Thank you for the responses. Yes the transmission was tilted so that's good that its normal than. The tc is a 231 with Teralow and 2wd low installed. I need to open both cases and swap out input shafts for sure. But when I bought it the guy said something about cutting the tunnel. I was originally going to pull it out and resell it, but now I think I will just leave it in.

what year is your replacement transfer case?

**gunshw301** · 03-11-2012, 03:33 PM

Not really sure. The speedo gears are long on the "new" tc, and I think they changed them in 93. So my guess is a pre 93. I know it's from a yj though. Thanks for the reply about 2lo, not going to worry about it then.

moonshinefuel · 03-11-2012, 03:52 PM

There's a fundamental difference in gear cut pre 1994. If you are considering swapping gears case to case, you need to verify what year the case is if you want to stay out of trouble. There's more to it, but you need to start there. There's a circular tag on the case, copy all of the information down on both cases.

**gunshw301** · 03-11-2012, 09:35 PM

Now you have me worried! I took a look at the cases. From input gear reference numbers on quadratec, it looks like my new case is a 91 or up. If that's the case would I just need to swap input gears? Gear cuts the same? I plan to put an ax15 in it at some point but not really until I trash the ax5 again. I hope I didn't just buy the Sye on this tc, that would make it an expensive used slip yoke eliminator.

moonshinefuel · 03-11-2012, 10:50 PM

Somewhere around the 2nd month of 1994, gear cut changed. It's good that you looked at the tags, but, providing more info is necessary, all the info on the tags, line for line, for the best answer, you need to provide. You can also call a company like Advance Adapters, or maybe jb conversions, and do the same thing, tell them what cases you have, and request gear swap info from them. They specialize in this, that's what they do.
After you get the gears out will also be revealing as the bearing shoulders changed with the gear cut, wide shoulder would be early cut, narrow bearing shoulder is later cut.
I would not worrie, I would just verify compatibility with what you have to work with, and go from there.

**gunshw301** · 03-12-2012, 05:53 PM

Thank you so much for the help. Got some pics of the transfer cases. Haven't torn them apart yet. Will be either tonight yet or tomorrow.

New transfer case ax15 tranny

Old case ax5 tranny

231 j 5209 7894 913 933 272

moonshinefuel · 03-12-2012, 11:36 PM

I am seeing this. However, call Advance Adapters to verify.
5209 7894 later gear cut.
5300 8212 early gear cut.
From what I see right now, they are not the same planetary gear cut.
Basically they are the same size transfer case though, not sure why any tunnel work would be needed. if your current one is good, I think it might be better to put the 2wd low from your recent t case purchase, into the original case, as opposed to swapping your original planetary gear, into recently purchased t case.
I would look into approaching it that way to get the job done possibly.

**gunshw301** · 03-14-2012, 02:00 PM

Alright, get both inputs out and they are not even close. The teraflex is on the left and the stock 231 is on the right. The base is not even close, probably an 1/8 larger on the stock input. So I have been reading and I think I have a early cut on the left and a late cut on the right. Not 100 percent sure though. Also been wondering if this teraflex input is of their own creation and I need a 21 spline from them. Sent an email to them but I guess they are busy. Notice how the channel is closed at the top of the Teraflex I can't find any on the Internet that look the same. Or does it even matter. I am just a lot confused at this point.
Novak has two 21 spline inputs, but one (late cut) is no longer available, I see this is the same on quadratec for mopar replacements as well. Any thoughts. Any teraflex gurus?

**gunshw301** · 03-14-2012, 02:30 PM

Seems the input I need is a teraflex part. I found a vendor for it, but it comes with a steep price tag. The only thing that's keeping me from buying is there is also a planetary for the 21 spline input. If I need that then I might as well buy a whole Teralow kit. Guess I need to call teraflex when I get a chance.