Welding Viscous Coupler in 249 - JeepForum.com
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post #1 of 20 Old 11-22-2019, 07:06 PM Thread Starter
cantwine
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Welding Viscous Coupler in 249

Has anyone had any luck just welding the viscous couple in your 249 and removing the front drive shaft? I think I may try this as just a cheap option to keep the jeep on the road until I can afford to build a 231 the way I want. Thanks for any input!


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post #2 of 20 Old 11-22-2019, 07:41 PM
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Originally Posted by cantwine View Post
Has anyone had any luck just welding the viscous couple in your 249 and removing the front drive shaft? I think I may try this as just a cheap option to keep the jeep on the road until I can afford to build a 231 the way I want. Thanks for any input!
Depending on what kinda metal it's made from I don't see why it wouldn't be possible....May also turn out to be a alternative for trailer queens

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post #3 of 20 Old 11-22-2019, 07:50 PM Thread Starter
cantwine
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Depending on what kinda metal it's made from I don't see why it wouldn't be possible....May also turn out to be a alternative for trailer queens

94 ZJ 4.5" on 31s

True that. I suppose since mine is already shot, Ill go ahead and weld it and report back on if it worked or not. The way I look at it I can just use it without the front drive shaft on the road, and If im gonna go for a day of wheeling, just through the front drive shaft back on.

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post #4 of 20 Old 11-22-2019, 07:56 PM
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True that. I suppose since mine is already shot, Ill go ahead and weld it and report back on if it worked or not. The way I look at it I can just use it without the front drive shaft on the road, and If im gonna go for a day of wheeling, just through the front drive shaft back on.
Any idea on what kinda metal it is? I'm not a welder but due to my last job I do know a good bit about welding

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post #5 of 20 Old 11-22-2019, 08:46 PM Thread Starter
cantwine
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Any idea on what kinda metal it is? I'm not a welder but due to my last job I do know a good bit about welding

94 ZJ 4.5" on 31s

Negative on that. Tried looking it up but couldn't find anything. The shaft and housing are definitely both made of steel, so as long as I get the temp set right, I think I can make it work. I saw some pictures of a guy that did it, and it looked like he just used a typical mig welder which is what Ill be using.

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post #6 of 20 Old 11-22-2019, 08:48 PM
wingless
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Mine was a rebuilt unit from STE Couplers (st3dave) on eBay.

He doesn't currently show that part, but he is a good contact.


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post #7 of 20 Old 11-22-2019, 08:49 PM Thread Starter
cantwine
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Originally Posted by Wolfeman1992 View Post
Any idea on what kinda metal it is? I'm not a welder but due to my last job I do know a good bit about welding

94 ZJ 4.5" on 31s

Here's the article I was talking about. Said he used a miller 225 mig welder and got good penetration.


http://mallcrawlin.com/forum/archive...hp/t-5157.html

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post #8 of 20 Old 11-22-2019, 08:53 PM
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Originally Posted by cantwine View Post
Negative on that. Tried looking it up but couldn't find anything. The shaft and housing are definitely both made of steel, so as long as I get the temp set right, I think I can make it work. I saw some pictures of a guy that did it, and it looked like he just used a typical mig welder which is what Ill be using.
Hmmm could be a form of hardened steel so standard 70 series should work if it is hardened your gonna need to preheat it and then heat treat it again after you weld it

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post #9 of 20 Old 11-22-2019, 09:29 PM
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I bought my last np 242 for well under $100. What is your time worth?

GW

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post #10 of 20 Old 11-22-2019, 10:05 PM Thread Starter
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I bought my last np 242 for well under $100. What is your time worth?

GW

Well I bought a 242 for 50 bucks, and it was leaking like crazy out of the rear shaft. Put a new extension housing and seal on it, and it turns out the main shaft is bent to heck. I think the guy I bought it from ran it on a lifted jeep without an SYE. I don't have a lift on my jeep yet, but I plan on doing one, so I am going to get a 231 and do a full rebuild on it including all bearings, seals, chain, and also do an SYE kit. So since I already have the 249 on my bench, with the viscous coupler sitting there, I figured the best option was to weld up the viscous coupler, put the 249 back in the Jeep, and drive it for a few months while I source all the parts to do the lift, and the 231 rebuild. This jeep is also my daily so I can't have it not running for very long, and with it being Christmas season money is tight and I can't risk spending 100-200 on a tcase and then still having to do a rebuild or throw more money at it because it has issues like the one I just bought.

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post #11 of 20 Old 11-23-2019, 09:35 AM
terpsmandan
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IMO if you run a 249 long enough, the coupler will bind itself up. That's why I replaced mine with a 231.
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post #12 of 20 Old 11-23-2019, 10:10 AM
wildbill23c
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Its a coupler that failed, so I don't see why welding it together would be a problem. Although if you mess it up you may have a non-operational Jeep till you get a replacement T-case or viscous coupler LOL. But hey its already broken why not give it a try. The viscous coupler failure was one of the main reasons I sold my 96 ZJ, it ran and drove great other than the hopping front end when trying to park due to the failed viscous coupler....but hey I guess at least they fail in an engaged state at least that's what it seems, so you still at least have 4WD unlike these electronic transfer cases now that when something fails you got no 4WD or AWD at all.
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post #13 of 20 Old 11-23-2019, 10:39 AM
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I was more thinking a budget tcase alternate for areas like mine that getting a 231 is actually difficult (junkyards are picked clean) but 242/249s are plentiful, for trailer queens which are very common where I live (lots of mud here so playing with your daily isn't recommended)

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post #14 of 20 Old 11-23-2019, 01:07 PM
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Maybe I'm just being dense, but it's my understanding that if the VC fails it's permanently locked. What is the advantage of welding it if it's already locked?
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post #15 of 20 Old 11-23-2019, 01:40 PM
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Originally Posted by kachink View Post
Maybe I'm just being dense, but it's my understanding that if the VC fails it's permanently locked. What is the advantage of welding it if it's already locked?
I thought it breaking meant it would slip under load? Could be 2 different ways of breaking one stops it from engaging and one from disengaging?

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