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SPARTAN LOCKERS are on sale BIG TIME at ROCKRIDGE 4WD!FLASH SALE! Open thread to reveil the Newest Sale @ ROCKRIIntroducing MONSTALINER™ UV Permanent DIY Roll On Bed Line

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Unread 01-05-2015, 04:40 PM   #1
ZGRay
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Join Date: Jan 2015
Location: Melbourne, Victoria
Posts: 2
Greetings from Australia

Happy New Year.

I'm hoping for some advice please.

I'm attempting to prepare my ZJ ( known as ZG down under ) for a week of touring/camping in the Aussie Bush. She hasn't seen much use for a while now, its had a whine from somewhere in the drive line which has progressed to include a light thump when under load driving straight ahead. The noise changes to a loud clunk during tight turns.
I suspect the Rzeppa joint in the front drive shaft is the problem.
Mine has the 249 Transfer Case with a double cardon at the TC and Rzeppa at the front diff.
I have removed the front drive shaft, drives real smooth without it, no whine or clunks and bangs. Inspected drive shaft, all looks OK to the untrained eye.

Last time out left side CV axle started to "twang" when pushed hard, replaced both front axles/CVs.
So far I have:
Checked for movement in relevant components.
Changed both diff oils, no signs of metal, both appear OK to the untrained eye, couldn't see any pitting/scoring etc.
Changed TC oil, came out clean.
I've turned front diff by hand, smooth and easy, noticeable backlash, guessing that's normal.
I could not turn TC by hand with it and transmission in neutral, drive shaft removed, is this normal?
Could the viscous coupling in the Transfer Case be the culprit?

Can someone point me in the right direction please.

Cheers
Ray

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Unread 01-06-2015, 10:54 PM   #2
1998_ZJltd
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1998 ZJ 
 
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Location: stockton, California
Posts: 414
Sounds like the VC in the t case ....

Lots of write ups on it here ..... no real hard but cost a little coin to do ....
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Unread 01-06-2015, 11:03 PM   #3
kg6mov
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1996 ZJ 
 
Join Date: Nov 2012
Location: Cupertino, CA
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Which year do you have?

The 249 always links the driveshafts even in neutral. Did you have both shafts removed when you tried to spin it?
__________________
1996 ZJ Green Laredo V8, 2.5" OME and Bilsteins, 33's, Holes drilled in the roof.
1998 ZJ Platinum Limited 5.9, Backyard parts fodder
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

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Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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Unread 01-07-2015, 05:28 PM   #4
ZGRay
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Join Date: Jan 2015
Location: Melbourne, Victoria
Posts: 2
Hello again,
Thanks for the responses, it's a July '96 build 6cyl.
I have only removed front drive shaft so far, so if I remove rear shaft next weekend and it still won't rotate, would I be correct in assuming it's the transfer case?

Cheers
Ray
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Unread 01-07-2015, 05:35 PM   #5
kg6mov
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1996 ZJ 
 
Join Date: Nov 2012
Location: Cupertino, CA
Posts: 4,768
That would be one hell of a bad day, but yes. If you remove both shafts the t-case outputs should spin freely together. You can also lift one rear tire with a jack and spin that to spin the rear shaft and thereby the front t-case output.
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1996 ZJ Green Laredo V8, 2.5" OME and Bilsteins, 33's, Holes drilled in the roof.
1998 ZJ Platinum Limited 5.9, Backyard parts fodder
1987 Mercedes 300D Turbo, the diesel daily, 30mpg in style

Quote:
Originally Posted by Texas ZJ1 View Post
I heard someone yell "mall crawler" from the back porch. I'll go see who said that. Be right back.
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Unread 01-08-2015, 12:13 AM   #6
siguy
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Location: staten island, new york
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hello downunder
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Unread 01-08-2015, 10:46 PM   #7
nicyousuckk
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Location: phoenix, arizona
Posts: 116
Australian... why are you into ZJ's when you all have the most awesome looking outback ute things?!
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Unread 01-08-2015, 10:51 PM   #8
SchizophrenicMC
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Quote:
Originally Posted by nicyousuckk View Post
Australian... why are you into ZJ's when you all have the most awesome looking outback ute things?!
There's a reason they're called GRAND Cherokees.
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