Alright so this is a 1993 Jeep Wrangler. We are currently taking out the transfer case
underneath the bottom. It was making a rattling noise. First step, take off the skid plate.
There are six bolts; 3 on either side. It was pretty rusted on there. I had to use a
cheater bar to take off the bolts. After that you get underneath here and take apart the
drive shaft that’s connecting it to the very…the the end differential. Then you
loosen up here on this. There are 4 bolts; one on either side. Take those apart so you
can pull this apart later. Then there are going to be 6 bolts that are inside between
the transmission and the transfer case. So there are 3 on either side. Make sure you
take those off. Before you do any of that though, make sure your connections, all of
your wires are taken apart cuz if you drop the transfer case with those still connected
you’re going to have a lot more expensive problem than when you started. Also make sure
you drain it. There’s a little drain plug here. Get all the liquid out. It will be a
little bit lighter for when you actually do need to drop it. The whole thing weighs like
probably 70 or 80 pounds. Then noise it was making when it was driving was this. So any
time that I was coasting, you know, along the road, if I would just take my foot off
the gas pedal to coast it would make that noise. I’m hoping it’s just the chain
inside. A pretty easy fix. It should, the chain itself, should only cost 80 bucks or
so. Anyway, so once we get it off I’ll let you know what happens. Alright so two more
things. The way to tell what type of transfer case you have is right here on this. As you
can tell mine is a 231 J. “J” is for jeep. Also when you’re doing it make sure you
support your transfer case. Like so I’ve taken down the bowl so it doesn’t bend anything.
As you can see we’re using a pretty high tech contraption of a cinderblock and a nice
little bowl we got from some girls. Alright so I finally got all the pieces in, it was
seriously a nightmare trying to get the chain back on. Basically you have to take every
part out just a little bit, like those main segments like the bottom gear that was attached
to this guard, and then this guard. Just take them out a little bit and then just kind of
like angle it all in and then just plop it in on one go. It seriously took me like 15
minutes to get it in lining everything up all right. I’m guessing it would be a whole
lot easier if you do as the manual says and take out this section right here if you get
this bolt out on the bottom. I just….We tried for probably 20 minutes to try to get
that bolt unstuck and it wouldn’t go. So anyway that’s it with the chain back on.
We’ll take it from there. Alright so we pulled it off. This thing gave us a little
bit of trouble. It plugs right in to this little hole right here so we just pulled that
out. And then here we got the whole transfer case. You can see those 6 bolts that were
stuck inside of that. Pretty straight forward. It took two of us to get it out. It’s a
pretty heavy little beast. And that is how you remove a transfer case from a jeep. Alright
so here we have the transfer case of a jeep. It’s a ’93 YJ. The transfer case is the
231 J. Just going to walk you through how to take it apart really quick. So once you
get this part right here, it’s a little guard, unscrew the 3 bolts that are holding
onto it. Then you got to snap it off in a clockwise direction. We were having some difficulty
getting it to go clockwise so just a sharp tap right here with a rubber mallet… broke
the whole thing off. Um just make sure you don’t scuff up any of those …the sealing…where
it seals to the main part of it. Then you have this little ring right here. It actually
goes in this little groove. This is a b to get out. We put two screwdrivers in that little
section right there and kind of pried it apart and then just wrapped a screwdriver around
the inside. Worked out well enough. Now we’re taking out these bolts right here that connect
this part to the base of the transfer case and then we’ll be able to pull that off
and see what else is inside. Alright so then we have…after we got off the top guard we
have the base of this. We took out all the different screws. You don’t need to take
out the sensor. The sensor’s fine. Then we ended up taking a wrench, putting it underneath
here, just popping that up. Popping this section up right there. It took some doing. About
3 guys and we finally got it. Go ahead and lift it off. And then this is what we’re
left with. You can pull this off as well. Make sure to disconnect that little tube right
there, who knows what that does but it should be connected on there. That’s where we’re
at so far. Alright so there are two little grooves…where’s the other one at…one
right here and one on the other side. And there’s also this right here which I always
use to pry off this side of it and that releases this half of the transfer case so we’re
going to pull it off. Alright so we finally got the top half of the transfer case apart.
We also found what the problem was. The chain goes right here around the gears. We ended
up just taking it off though. You’re supposed to…the manual said you’re supposed to
take this part off first and release that before you can get it done, but we just juggled
this around till the chain came off itself. As far as what’s wrong with the whole device…let
me pull this out…alright so I tipped it over so we got a better view on it. So these
come apart here. This whole mechanism comes apart as well. So we got the main shaft there.
Got that gear. And what…the part that screws on that goes in-between this little groove
right here, that’s the part on my machine that was messed up. So you can tell right
here that it’s kind of ground down along the edges. And then if you look closely in
here as well you can see like these silver bits of metal that have been ground off. And
that’s what our problem was, the whole rattle that was coming from it. So I got a new piece
for….I got this and all the little protectors on it for about 60 bucks from I believe Morris
4x4. You can just do a Google search for them. They have some pretty good 4x4 parts. Anyway
so I’m going to replace that and then put the whole thing back together. And I’ll
walk you through that as well. Alright I just want to show really quick that it doesn’t
make that same noise anymore that it was making before. The clicking noise is now gone. So
that was the part that was replaced that was the problem. Just this right here, you can
see where it’s kind of ground away from the gears inside. So it was this part that
was making the noise. Alright so we’re putting on some gasket on right now just so we seal
it up again and it will be tight and won’t leak at all. The particular gasket that we’re
using is this high temp red silicone so it will work out well for the transfer case.
So you can just kind of see how thick that we’re putting it on there. Just make sure
it goes up and around each of the little bolt holes as well. Alright so one super important
thing is to make sure that is it in 4 wheel drive. So you got your two pins, your top
one and your bottom one, mounted as high as possible. Otherwise, when you go to put in
this little ring at the top it won’t sit high enough and you won’t be able to get
it on. Trust me, I’ve done this 4 times now. Alright so when you’re mounting…now
we have the first half mounted on, the second half make sure you clean this off as clean
as you can get. Make sure that there’s no red, like epoxy stuff underneath this cuz
it needs to sit flush. Put the pump cable inside of that and put this down as flush
as you can get it. Make sure you align the gears and everything. And then be pretty generous
with the high temperature silicone. You just want to make sure it’s not going to leak
at all. And then go ahead and put the two on aligning all the necessary parts. Alright
so I’ve gotten this part on. If you did decide to take out the sensor it’s pretty
simple to put back on as well. You can either put it on as I did as a whole unit or you
can put the metal part on first and the sensor on later, I’ve seen it done both ways. As
far as this o-ring goes, I did finally break down and buy a pair of these to help spread
open the part and remove it. I’ve actually…we had a huge problem trying to get enough space
to put the o-ring there first. It turns out that this bearing right here comes out. It
was pulled out about a millimeter too far and so I…I seriously spent probably 5 hours
taking apart and reassembling the whole unit trying to figure out where that extra millimeter
went. So hopefully that will save you some time. Just make sure that bearing is planted
all the way in. It’s pretty solid I just have a rubber mallet that I used. Anyways
so I’m going to get this ring on and we’ll take it from there. Alright and that is what
it looks like with the o-ring in place. Alright once again copious amounts of the red stuff.
Go ahead and slide it on top. Slide it down. Make sure the holes line up. There’s a right
pattern for that. Then you got to make sure the bolts are in the right spot and I will
show you where the funky bolts are in a second. Alright so when you’re putting the whole
thing back together there are a few “off” bolts that aren’t the same as the rest of
them. This one up here at the top and there’s one of the different bolts…you need a different
socket head for that. I had to buy an extra one. Anyway in the second layer here on the
corner of the transfer case, it’s this one. And then on the bottom layer there are two
that need washers. And it’s the same ones that have the little guiding rails when you
put them both together. So it’s this one and at the other side, it’s that. So both
of those….all of those will be the different bolts when you’re putting it all together.
Anyway, so it’s all done now so just got to put it back in the Jeep and hopefully it
all works. Alright so here we are underneath the Jeep again. We do have the transfer case
mounted back underneath the Jeep. Let me explain how we did it. We put the little seal back
on the transfer case and mounted up onto this, you know, bolting it in. I believe it’s
a 14 millimeter ratchet that you need. I put the drive train back in. You can see here
all you need to do is just put it in place. We put the transfer case in first and then
just lifted it up enough to slide this into place, and then put on the little screws that
you can see are required as well on this back drive shaft. This one was easier. You just
have to make sure to line up the direction that this if first before you put this end
into the transfer case. So yeah, that’s where we’re at right now. The transfer case
is in. I’m going to make a video to show how to do the transfer case fluid. Basically
you fill it through this one and drain it through this other hole down here. So all
I’m going to do is I’m going to take this off and then pump the fluid into it and close
it up and it should be good. This is the next morning after I put all this red stuff on
that was very liberal in putting on, so it’s had time to dry and everything like that so
it’s good now to put fluid in. We should be good. Alright I filled it up just enough
so that the oil would start coming out of this little plug right here, and then all
you got to do is tighten it and you’ll be good to go. And that’s how to change the
transfer case fluid in your transfer case. Alright here I am underneath the Jeep again.
I have this big plate, the support that holds up the transfer case and transmission. Basically
what I did was I propped it up with my jack from my Tacoma and I put these two bolts in
right there to bolt it together and then once it’s up, then you can put the bolts in on
the sides. So I got this one in and it’s pretty just straight forward from there. I’ve
done it all myself so it doesn’t need to be a big multi-person job. Pretty straight
forward. Alright the Jeep is back up and running. This is the Wrangler we were working on. So
underneath here I got the support and scrape thing back bolted on. It was pretty rusted
on there so I sprayed a little bit of lubricant in each of the bolts and it worked fine. Make
sure you tighten up those two things as well; I kind of forgot to do that. But I did turn
the rig on and everything works great. I’m super…I’ve never worked on a project like
that before and it was fairly simple and straight forward as long as you get everything that
you took off back in the right spot again you’re good to go. Anyway, if you have any
questions feel free to ask.