Hi guys, this is my first post so be gentle! I have searched up and down for the answer to my question but have had little luck.
Here is whats going on, my ZJ runs and sounds great most of the time, just had the U joints and front drive shaft done seemed to be working great, but then I took off from a stop light yesterday and noticed what sounded like a popping noise coming from the Transfer case. I took her off road today and climbed some hills. The popping/clicking gets really really really bad when the jeep gets climbing (does not do it all the time just when there is a lot of torque going into the TC). Noticed it really bad when going in reverse back down the hill but only when I had pressure on the breaks. So my question is what do I do to fix it? Is it the whole TC or just some part of it?
If you are mechanically inclined and feel comfortable pulling your tc its not that bad. If you want to keep the 249 then do the vc too! I would suggest swapping to a 242 or a 231 especially if you don't like the full time 4x4 and would like the option of 4x2. It would be easier to do just a swap too, check out the sticky for the tc swap it will give you all the info you would need to do a swap.
Thanks man, I do like the full time 4wheel, but its killer on tires and gas. Dono about doing the VC on my own, I am pretty good with stuff but that kinda freaks me out. I did the break master and the breaks this week as well as the front drive shaft. I kinda knew I was getting into a project vehicle, I got it for a killer price, and its not my daily driver so maybe I will take the jump and replace it.
When changing the VC and chain does the TC need to be out of the jeep, or can you just take off the back side of it?
You have to pull it out but that's the easy part. There are a lot of parts inside that have to go back in the right order. Before trying a job like that I would do so searching there are a lot of threads out there with pics or find someone to help you that's done it before. Getting a rebuilt unit is not a bad idea if your having doubts because once you crack it open who knows what damage you may find and you should do a complete rebuild anyway. Plus just swapping is not too difficult and can be done in a day or two if you have a few problems. Having the 4x2 option wouldn't save you any mpg and excessive front tire wear is a sign of a bad vc. Before your tc took a dump if you ever noticed when turning sharply like in a parking lot that the front end bounced or the tires chirped then your vc was bad.
Thanks for the help man, I think I will prob just get a rebuilt one. Seems like the easiest way, and I found one for about the same as a new chain and a VC. Its a task, but needs to be done. I am up for the challenge though!