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Unread 09-20-2013, 06:57 PM   #31
rdkendrick
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2003 WJ 
 
Join Date: Jan 2013
Location: Cincinnati, Ohio
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Quote:
Originally Posted by 914pete View Post
Another issue, when I shift into reverse and start backing up, the back up lights don't come on. I have to move the shifter between reverse and neutral and hold it there in order to keep the back up lights on. The jeep dealer tells me I need a new neutral safety switch. Does that seem right?
Just checked and I still have the pictures on my iPad. The 42RE has neutral/safety switch, but the (5)45RFE has a Transmission Range Sensor. There's also a Brake-Transmission Shift Interlock adjustment you can do.

Sent from my iPad using my fingers

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Unread 09-22-2013, 07:14 PM   #32
914pete
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Good info. It was the Neutral Safety Switch. Simple removal/install. Took 5 minutes. 1" deep socket to remove/install. Back up lights work again $28 (Mopar). Dealer wanted $150 to replace it.
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Unread 09-22-2013, 07:25 PM   #33
914pete
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So, I removed the front DS. Very easy. Took 10 minutes. Drove it at highway speeds without the DS and no more noise/vibrations. While removing it, I think I found the problem with the loud grinding knocking going on when the 4WD is engaged. The front DS rear CV joint is shot. The boot was disintegrated, bearings exposed, rusty dry and gritty in there. I could barely move the spline inside the CV joint.

My front drive shaft has a universal joint at the differential and a CV joint at the TC. I can't seem to find a diagram of this set up on the web? I'm hoping I can just replace the CV joint and the spline as a unit rather then buy a whole new DS which I can't seem to find mine anyway. Any thoughts?
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Unread 09-22-2013, 09:08 PM   #34
WJ297
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I would personally look into the IRO conversion kit to a double cardan drive shaft. This one has two u joints at the t case and one at the diff. You would only need one yoke (for the t case). Although it is a little pricy but I did the conversion and I have no complaints, no vibes and it seems to be a lot stronger. I had the cv at both ends.
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Unread 09-22-2013, 10:05 PM   #35
brouwmat
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Quote:
Originally Posted by WJ297
I would personally look into the IRO conversion kit to a double cardan drive shaft. This one has two u joints at the t case and one at the diff. You would only need one yoke (for the t case). Although it is a little pricy but I did the conversion and I have no complaints, no vibes and it seems to be a lot stronger. I had the cv at both ends.
Agreed .. Either that one or look at a ZJ shaft. I bought mine and rebuilt it for about half the cost of a new one. Plenty of threads on this on the site.

Mine did the same thing and from your description it was the same shaft.
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Unread 09-23-2013, 07:12 AM   #36
914pete
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Thanks for the advice however, I need to do this as inexpensively as possible. My jeep is totally stock, no lift. I got 210,000 miles out of the first DS. Is it odd that I can't find my DS on Google anywhere? I've seen plenty with the CV's at both ends.
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Unread 09-23-2013, 07:24 AM   #37
skain8
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The stock rzeppa style shaft is perfectly fine for your application, and is a lot smoother during operation than the coventional double cardan. You should be able to find replacement/rebuild parts online. Or, visit your local driveline shop.
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'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
'99 XJ: stock
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Unread 09-23-2013, 07:41 AM   #38
mikeyc1821
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i had the same drive shaft as you, Pepboys can get a rebuild kit for the rzeppa joint for about 125 bucks... I was lifting my jeep 4 inchs, so i went and got a double cardon DS from an 04 4.7 wj and the yoke for the Xfer case..

If you want you can buy my old driveshaft... Its not wiped right out and worked fine untill i lifted my jeep... I would however rebuild it anyways...
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Unread 09-23-2013, 07:47 AM   #39
914pete
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Quote:
Originally Posted by mikeyc1821 View Post
i had the same drive shaft as you, Pepboys can get a rebuild kit for the rzeppa joint for about 125 bucks... I was lifting my jeep 4 inchs, so i went and got a double cardon DS from an 04 4.7 wj and the yoke for the Xfer case..

If you want you can buy my old driveshaft... Its not wiped right out and worked fine untill i lifted my jeep... I would however rebuild it anyways...
Thanks. My DS is good just need the CV. I will probably replace the universal joint too while I have it out.
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Unread 10-11-2013, 06:35 AM   #40
914pete
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Welp, all I needed was the rear CV joint on the front drive shaft. Fricken Jeep dealer charged me $120 to tell me the transfer case and front drive shaft needed replacing to the tune of $3700 for parts only....Probably another $1000 for labor. Bastards! Does anyone actually FIX anything anymore? I bought a CV joint on Ebay from Detroit Axle for $57.00. Easy fix. I couldn't see anything wrong at all with the front universal joint so I left it. 4WD works great again, no noise at all. Thanks for the help fellas!
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Unread 08-06-2014, 05:47 PM   #41
ballyhoo2014
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Question about original post

The OP said he drove his 2002 WJ for 1.5 years in 2wd and it was fine in spite of the TC problem.
Is the same thing possible in the 2004?

Thanks in advance, folks.
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Unread 08-06-2014, 07:29 PM   #42
brouwmat
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He didn't have a TC issue. It was the rear CV on the DS. Do as he did and remove it before you do anything else. If that resolves any vibration issues you have then it is likely that your issue is just the DS.

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