Can a backyard mechanic rebuild a Jeep transfer case?

tagger · #1 01-26-2005, 09:55 AM

96 Grand Cherokee Larado, V8. Transfer case output shaft bearing to front drive is shot. Lots of play and vibration at higher speeds. Can this be rebuilt by just disassembling and installing new parts or is there special tools and a whole lot of experience and training needed to rebuild a transfer case? Should I just buy a rebuilt one and stick it in? Should I pay the $3K to a jeep dealer and have them replace it for me? Can the unit be removed and replaced with the jeep on car ramps or do you need special jacks and and overhead lift?
Thanks,
doug

dksob81 · #2 01-26-2005, 02:13 PM

Well tag, thats alot of ?'s. Yes indeed you can do this yourself, it is not hard there are no special tools needed. it will be alot easier to replace the bearing if you remove the Transfer case from the jeep, the only thing I suggest is making sure you mark the relationship of the driveshafts to yoke (this a a necessity for driveshaft balancing) and before your take the transfer case off the tranny and before disconnecting the rear driveshaft loosen the yoke nut (front yoke) - you might be able to do this with the rear driveshaft discconected, just need a pipe wrech (monkey wrech) to hold the yoke while you turn the turn.

tagger · #3 01-26-2005, 02:57 PM

Quote:

Originally Posted by dksob81

Well tag, thats alot of ?'s. Yes indeed you can do this yourself, it is not hard there are no special tools needed. it will be alot easier to replace the bearing if you remove the Transfer case from the jeep, the only thing I suggest is making sure you mark the relationship of the driveshafts to yoke (this a a necessity for driveshaft balancing) and before your take the transfer case off the tranny and before disconnecting the rear driveshaft loosen the yoke nut (front yoke) - you might be able to do this with the rear driveshaft discconected, just need a pipe wrech (monkey wrech) to hold the yoke while you turn the turn.

Thanks for the information. This has been a learning experience. I now can replace a total steering front end from ball joints to bushings/ suspension/ radiators/brakes/calipers/rotors/brake assist modules/and now I am going for the transfer case.... this has been one heck of an educational project.... all I wanted was a 4 wheel drive to get around in the colorado mountains when it snows...

dksob81 · #4 01-26-2005, 05:12 PM

yea same here, I live in Pennsylvania, and I travel to northern Pa a couple times during the winter, and without 4WD it's hard to gt through the mountains.

I love my Jeep, but after coming here I see all the problem that some ppl have with there ZJ's and it makes me wonder. but I've had it for a year now and no major problems.

mx52nv · #5 01-28-2005, 09:51 AM

Quote:

Originally Posted by tagger

Thanks for the information. This has been a learning experience. I now can replace a total steering front end from ball joints to bushings/ suspension/ radiators/brakes/calipers/rotors/brake assist modules/and now I am going for the transfer case.... this has been one heck of an educational project.... all I wanted was a 4 wheel drive to get around in the colorado mountains when it snows...

hey, I'm in Monument, Co. Let me know where you are at. I would love to help and learn something new.

rmoore5 · #6 01-28-2005, 10:49 AM

Tagger if you are sure it is the output shaft bearing, it can be changed with the transfer case in the car. Let me know which case you have I may have the exploded views and the procedure.

Rick

jtp97 · #7 02-21-2006, 10:17 AM

Tagger I am also having the same issue, I had the trany fluid flushed and changed last Thurs, Sunday got a noise from the transfer case at first at thought it was my brakes becasue I was in the mudd 4x4. Did some trouble shooting and found the high pitched noise coming from the front of the transfer case, just behind the front bearing retention piece. If anyone also has some recomendations on what to check on please let me know.

JP

jeeperphil · #8 02-21-2006, 07:56 PM

The only special tool needed is a good transmision snap ring pliars. I swapped my 249 out with a 242 from a junk yard. Had to pull it back out and rebuild it! I took pics of the whole tear down. I found a rebuild manual for the 242 at atsg web site. It has line drawings. so I copied the text and added my pics. I'm thinking of coping it and put on e-bay. see if I can make a buck. The original manual is easy to read and understand. My local dealer removed two bearings that I couldnt get out with my tools. did it for pennies. Any exploded view of case can also be used to do the job. Manual at atsg was about 20 bucks.

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