Have I destroyed my transfer case?? - JeepForum.com
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post #1 of 3 Old 10-10-2021, 10:02 AM Thread Starter
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Join Date: Feb 2017
Posts: 29
Have I destroyed my transfer case??

2004 jeep wj Laredo 4.0, np242, transfer, 2 1/2" lift
Truetrac in the Dana 35 rear
Stock Dana 30 front

Ok, I was on my 3 front drive shaft, c.v. joint boot failure and decided to go to a double cardan style drive shaft. For proper length for the drive shaft build I needed to install new front yoke on transfer case output.
I put transfer in low 4 per a video I watched, to keep output shaft from spinning. I broke the nut loose with a breaker bar with minimal effort, and removed with an impact gun.I then replaced old output shaft seal.Next I pulled cv yoke with a flywheel puller, again popped loose very easily, and installed new yoke just using my torque wrench and tightened to 95ft lbs.
90 to 130 ft lbs was recommended. After a refill of atf I tried to put in full time 4wd to spin yoke in seal. It then made a loud clunking noise. I put in 2wd and backed out of garage and tried again. I was moving in reverse when I shifted and it simply lost all motion and made a clicking sound. I immediately put back in 2wd and it goes fine.

Does the transfer case need feedback from driveshaft to engage?
Or did I screw something up?

The new driveshaft comes in Wednesday to test.
Any input would be appreciated.

Thanks, wjinnc

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post #2 of 3 Old 10-10-2021, 06:31 PM
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2004 WJ 
Join Date: May 2020
Location: Aroostook County
Posts: 291
I'd say it sounds normal. I don't think it will move in full time if one of the driveshafts is removed. If you lock it in part time it should move fine and 2wd of course.
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post #3 of 3 Old 10-10-2021, 07:28 PM Thread Starter
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Join Date: Feb 2017
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Yep, that's what is was. I thought I had done messed up. I took it down the road and put it in part time 4wd. It went right in. It did pop one time when I tested reverse. Thanks so much for the reply
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