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Unread 08-20-2011, 09:16 AM   #1
tnavz
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1994 ZJ 
 
Join Date: Aug 2011
Location: holmes, ny
Posts: 42
Transfer Case Rebuild Begins. Any tips?

I am going to start yanking out my 249 to replace the viscous coupler tomorrow. Is there anything I should know to make it easier?

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Unread 08-20-2011, 12:48 PM   #2
a70eliminator
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Join Date: Dec 2004
Location: Kent Ohio
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I've done 3 of them all withing the vehicle working from underneath, my modified set of snap ring plyers is all I need, take off the plate on top using a torx bit on a 1/4 socket and ratchet ratchet, take the bolts out of the rear housing, stick my plyers in from above and working by feel and a dental mirror, spread the reatiner ring and pull the rear howsing off, the rest is simple.
Putting it back together is easier, I wedge a tiny block of wood in the reatiner spring ring to hold it open, slip the housing back into position and pull the wood block out, done! bolt everything back up, I have it down to about a 1hr job start to finish.
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Unread 08-22-2011, 05:52 PM   #3
tnavz
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job is done. thanks
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Unread 08-23-2011, 08:04 PM   #4
KillaJeep4569
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2006 WK 
 
Join Date: Jun 2010
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Quote:
Originally Posted by tnavz View Post
job is done. thanks
How was the Job? I have to replace the Sun gear since I am doing a swap. was it hard and how long of a job you think it is? Thank you and cheers
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Unread 08-24-2011, 04:16 PM   #5
tnavz
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Location: holmes, ny
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The job wasn't as bad as I thought. If you are replacing the sun gear just plan on an extrs hour or so of time with the transfer case on your work bench. If you have some help and all of the tools, I think it would take around five hours. Thats just a guess though. Good luck. Oh and the only glasses I bang anymore are Becks N.A. It's not as much fun.
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Unread 08-24-2011, 07:26 PM   #6
KillaJeep4569
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Originally Posted by tnavz View Post
The job wasn't as bad as I thought. If you are replacing the sun gear just plan on an extrs hour or so of time with the transfer case on your work bench. If you have some help and all of the tools, I think it would take around five hours. Thats just a guess though. Good luck. Oh and the only glasses I bang anymore are Becks N.A. It's not as much fun.
I dont Bang glass haha, I use the glass for other purposes hehe....
But I should and will have the tools plus an extra hand.

How long did it take you to remove it? Any steps you recommend or do extra???

And is there anything out of the ordinary you did or need to do?

I also want to fix my Original TC. I think the Shift Fork is out of place because the 4wd Low Doesnt work, just Neutral there. I banged the TC on a Rock trying to climb over, Tire slipped and bang. What do you think?
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Unread 08-25-2011, 06:16 PM   #7
tnavz
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1994 ZJ 
 
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Location: holmes, ny
Posts: 42
it will probably take a couple of hours to jack up the jeep and remove everything. as far as losing 4 low you probabaly just bent the linkage on the outside of the t-case. i dont know how much time i would spend on fixing up the 249 if you have something else already.
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