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Unread 05-04-2013, 08:51 AM   #1
UZI4U
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TJ transfer case to YJ problem.

I went to swap out my TX case last night and it won't engage completely. They are both 23 spline 231's, but the TJ case has a ring ahead of the input shaft splines that keep the AX-15 output shaft from fully engaging the 231 input shaft by about .75". Anyone ever encounter this? What do I need to do to make it work? Another input shaft?

I've never torn into a transfer case, but I've got a work bench and I'm not afraid to use it.

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Unread 05-04-2013, 08:57 AM   #2
Louie4
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Take a pic and post up. Here is what my old one looks like. It's a 23 spline.
np231.jpg  
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Unread 05-04-2013, 09:10 AM   #3
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The red tube points to the offending piece behind the splines. The other pic shows how the piece had a smaller ID than the splines. By looking at an exploded view, it might be a bearing. I'm not certain though, as I've never had one of these apart.
231a.jpg   231b.jpg  
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Unread 05-04-2013, 12:56 PM   #4
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I don't have a pic of the original TX case...it's in the Jeep.
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Unread 05-04-2013, 01:20 PM   #5
Louie4
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Mine does not have that. This picture sucks but I just looked at it. You may need to swap input gears. I don't think it's that bad. Maybe the tranny was a New Venture on the TJ?
0504131515.jpg  
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Unread 05-04-2013, 04:33 PM   #6
UZI4U
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That's how the original looks. Any tricks to changing out the input shaft?

Also, the case casting numbers are both the same.
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Unread 05-04-2013, 04:47 PM   #7
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I didn't see that on mine but then again it had a teralow.
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Unread 05-04-2013, 06:04 PM   #8
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Quote:
Originally Posted by UZI4U
That's how the original looks. Any tricks to changing out the input shaft?

Also, the case casting numbers are both the same.
Get some good lock ring pliers! I went to sears and bought theirs and have done three cases now. The hf pair I had could not do one case. The sears I consider barely sufficient, but they do work.

Crack the case in half and pay attention as you pull things apart in order to remember how it goes back together. If you have any kind of me mechanical ability it really is pretty simple.

I can't remember the exact steps, but you will see what you need to do as you go along. Swap out the inputs and then reassemble. I can't remember if the planetary gear in the stock 231 is serviceable or not. If you have to take the input out of the planetary make sure it is clocked correctly (this may not apply on a 231) I only mention it because of my Tera low it was an issue for me. Tera flex has a good video on YouTube if you have to take it apart, watch the video first, it will help keep the gears aligned. Basically they just tell you to zip tie the planetary gears in place together.

Good luck, you will be fine. I think its kind of fun actually.
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Unread 05-07-2013, 06:20 AM   #9
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Will do in the pliers. Thanks!
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Unread 05-12-2013, 04:39 PM   #10
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Anyone have a pic of the rear of an AX-15 output shaft? More specifically, how far in can the input gear go? I found a donor 233 TC with the right input gear, but the shaft portion protruding is about 1/2" or so longer than the shorter shaft. I need to know if I have enough clearance inside the tranny to accommodate the longer input gear shaft. I don't want to take it all apart to find out it doesn't work and have to put it all together again.
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Unread 05-12-2013, 05:09 PM   #11
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I swapped input planetary sets a few months ago, myfirsttime tearing into a 231. It was actually pretty easy. Pay attention to all the parts and pieces. I layed them out in the order they came out and cleaned everything. I did it on the floor of the garage and used a big piece of cardboard layed out. Worst part was the snap rings as previously stated.

Feel free to ht us up for any help or questions.
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Unread 05-12-2013, 06:37 PM   #12
UZI4U
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I basically need the compatibility of the longer input gear shaft with my AX-15. If they will work together (same number of splines, just longer), I can swap them out.

The later 233 is an electronically switched 231 is the only difference. I won't be using that switch, obviously.
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