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post #46 of 66 Old 07-16-2019, 06:57 AM Thread Starter
Zakman
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Quote:
Originally Posted by NashvilleTJ View Post
Glad you made it out to Moan. Moab Rim is one of my favorite trails out there.
Loved Moab! Wife and I were just out there in April for hiking (yes, rented a Jeep to run Hells while there.) Also, going back in September for a week of wheeling. Can't wait.

BTW - glad to hear you're on the mend! Absolutely love your LJ.


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post #47 of 66 Old 07-16-2019, 07:18 AM Thread Starter
Zakman
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April 2019 - Moab Trip

My wife and I enjoy visiting the various National Parks to hike. This year, we went to Moab to hike Arches NP and Cayonlands NP. 3 days of hiking each park, a day at Dead Horse Point, and a day seeing the town of Moab. We did rent a Jeep (JL on 37s) and ran Hells for a sunset cruise.

Pics from Arches NP:
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post #48 of 66 Old 07-16-2019, 07:24 AM Thread Starter
Zakman
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Cayonlands NP:
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post #49 of 66 Old 07-16-2019, 07:28 AM Thread Starter
Zakman
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Dead Horse Point State Park:
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post #50 of 66 Old 07-16-2019, 07:34 AM Thread Starter
Zakman
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While in Moab, you can't be there without wheeling. So, contacted Outlaw Jeep Adventures to rent one of their new JL's on 37s. We ran Hells Revenge for a sunset cruise:
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post #51 of 66 Old 07-19-2019, 09:01 AM Thread Starter
Zakman
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So, after our vacation out West, I finalized my Jeep trip to Moab for September 2019. Clean up some issues, and improve others prior to heading west. Only other event on this year's schedule was JJUSA Badlands in June, where I happen to be a guide.

First on the list was to clean up the battery terminals and replace the OE battery cables.

Second, was to add a new switch panel and relay box. Added rock locks and replaced the CHIMSL with a Rigid Multi-Function Brake Light / Chase Light. (Brake, chase, strobe, reverse, and courtesy lights.)

Third, finally got around to addressing the fuel overflow issue. When I got the LJ, I installed teh GM filler neck, knowing that was a temp solution. Genright came out with a fuel pump access panel, so now was the perfect time to install the panel and fix the rollover valve inside the tank. Removed the GM neck and replaced with the OE neck.
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IMG_3042.jpg   2019 LJ - Spod Fuse Block - 020519.jpg   IMG_3043.jpg   IMG_3044.jpg   2019 LJ - Spod switches - 020519.jpg  


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post #52 of 66 Old 07-19-2019, 09:14 AM Thread Starter
Zakman
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That leads to May 2019. Had a trail clean-up weekend for the JJ down in Attica, IN. It's a one day detail, so I figured, just drive the Jeep. What can go wrong? lol

On the trials, the Savvy Mid-Arm was great. Didn't really push it, but it was nice and stable where we went. Felt better planted going uphills.

On the way back home, 30 mins from my last fuel stop (did check for leaks, etc) and 1 hour from home, I started getting a major vibe. Started to slow down and then BOOM. Looked over to the side, and I could see orange under the Jeep. Immediately pulled over and stopped. Looked under the skids to see FIRE. Quick burst from one of my fire extinguishers, and out.

The xfer case exploded in half. Front DS was loose from the case, chain parts all over, and the DS cut the fuel pump wire harness and xfer case shifter cables. Quick call home to have the better half get the truck and trailer.

Here's the end results:
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IMG_2951.jpg   IMG_2949.jpg   IMG_2946.jpg  

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post #53 of 66 Old 07-19-2019, 09:20 AM Thread Starter
Zakman
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So, then began a search for the elusive NV241OR xfer case. Finally found one and started to rebuild it. All new bearings, seals, and chain. New Adams Driveshafts front and rear. Upgraded the rear from a 1310 to 1350 U-Joints.

While I had the UA down, I did a trans flush, new filter, and fill. Then replaced the front exhaust section header to muffler with Flowmaster kit. Deleted the 3rd cat while I was at it.

Last pic is the aftermath leftovers.
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2019 LJ - 241OR - 1 case.jpg   IMG_2975.jpg   IMG_2976.jpg   IMG_3004.jpg   IMG_3041.jpg  

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post #54 of 66 Old 07-19-2019, 10:41 AM
07wurubi
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Wow. Don't hear much of the 241s doing that. Or at least I haven't.


Where did you source the parts to rebuild the replacement t-case from? Mine has over 200K on it.

Mike Fox

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post #55 of 66 Old 07-23-2019, 10:10 AM Thread Starter
Zakman
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Quote:
Originally Posted by 07wurubi View Post
Wow. Don't hear much of the 241s doing that. Or at least I haven't.


Where did you source the parts to rebuild the replacement t-case from? Mine has over 200K on it.
Hey Mike,

The case exploded, from I can figure out, either low fluid from a small leak on the rear output shaft, or the front output bearing seized.) I have heard of the front DS CV failing, thus taking out the case, but I had no signs or sounds of that prior.

As for the rebuild, various sources, as the 241OR is the oddball xfer case.

Rock Auto - case bolts, studs, misc small parts
Novak (have to call, as they don't list on their website)- rebuild kit
Cascade Transmission Parts - Chain

Also see if you had the TSB on the extension housing done while you're in there.
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post #56 of 66 Old 07-23-2019, 10:37 AM
07wurubi
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After I bought my LJ Rubi last year, I was out on a test drive and the front drive shaft CV came undone at the t-case yoke. Made a God awful banging sound beneath my feet. I was able to pull over and had my gf bring me some tools to remove the shaft. Thankfully it did not take out the case. But it did damage the yoke flange. I replaced it with a new yoke that was compatible with the front driveshaft I put in when I swapped my axles around between my TJ (sold) and it. All good now. But when it happened, I expected to see atf pouring from the case.

Mike Fox

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post #57 of 66 Old 07-26-2019, 08:22 PM
Aardemae
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Quote:
Originally Posted by Zakman View Post
That leads to May 2019. Had a trail clean-up weekend for the JJ down in Attica, IN. It's a one day detail, so I figured, just drive the Jeep. What can go wrong? lol

On the trials, the Savvy Mid-Arm was great. Didn't really push it, but it was nice and stable where we went. Felt better planted going uphills.

On the way back home, 30 mins from my last fuel stop (did check for leaks, etc) and 1 hour from home, I started getting a major vibe. Started to slow down and then BOOM. Looked over to the side, and I could see orange under the Jeep. Immediately pulled over and stopped. Looked under the skids to see FIRE. Quick burst from one of my fire extinguishers, and out.

The xfer case exploded in half. Front DS was loose from the case, chain parts all over, and the DS cut the fuel pump wire harness and xfer case shifter cables. Quick call home to have the better half get the truck and trailer.

Here's the end results:
Lucky you had the extinguisher handy. A friend of mine just lost his JK to a fire under these same circumstances, transfercase exploded, caught on fire, and it was a total loss! Great build by the way!
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post #58 of 66 Old 07-26-2019, 09:38 PM
Kluk Ztopolovky
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you are a really skilled car rebuilder , the new Jeep looks so very cool
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post #59 of 66 Old 10-01-2019, 07:21 AM Thread Starter
Zakman
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Moab Trip - Sept 2019

Ever since my last trip to Moab for wheeling, we've been planning on going back. Got ten of my good wheeling buddies together for an epic week. Most of my friends have never been out west and was an eye opening experience for sure.

After 26 hrs and 1600+ miles.........

We arrived in the afternoon on Sunday the 15th. After checking into our hotels, unloading the trialers, and grabbing bite to eat, we decided to hit the trials.

Sunday - Fins & Things - Warm up
Monday - Hells, inc Gate and Escolator
Tuesday - Rim & Cliffhanger
Wednesday - Metal Masher (Side trip to Gemini Bridges and Deadhorse Point State Park) and Fins at Night
Thursday - PSM and Hells at Night
Friday - GBR

Our group was a good mix of new and old school
2 LJs
2 CJ-7s
1 YJ
1 TJ
4 JKs

Some highlights:
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IMG_8573.jpg   IMG_8473.jpg   IMG_8483.jpg   IMG_8524.jpg   IMG_3124.jpg  

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post #60 of 66 Old 10-01-2019, 07:27 AM Thread Starter
Zakman
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Moab Trip - Sept 2019

More pics:
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IMG_3173.jpg   IMG_8575.jpg   IMG_3159.jpg   IMG_3115.jpg  
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