Transfer Case

Team J.a.G · **Posted:** Tue May 19, 2009 2:03 am

A few week-ends ago whilst driving off road(nothing hard core) a clicking type noise was noticed coming from under the car.
At first I thought it was a branch caught underneath. The noise speeds up and down with the revs of the motor/drive shaft. My mechanic has located the sound coming from the transfer case and has thought that maybe part of the chain inside has come apart and hitting the inside of the casing :?:

Does anyone have any experience with this sort of problem, in particular an with 02 KJ :?:

And what, if any, damage could happen if it is driven until repairs are carried out :?:

pipeliner · **Posted:** Tue May 19, 2009 2:07 am

Unless you select 4wd the transfer case is just being rotated by the front driveshaft and is not transmitting any power, so it is unlikely to cause significant damage to any of the driveline components.

It may wear through the aluminium casing if the rubbing is severe enough. The worst thing I can think of is that the chain will break and jam the front drive shaft, which would lock up your front wheels in a hurry - not a pleasant thought.

These thoughts without examining the transfer case layout and operation, so I could be as wrong as I usually am!

Team J.a.G · **Posted:** Thu May 28, 2009 7:30 pm

Further investigations have now shown that the transfer case is all A OK, however the connection of the c.v. joints on the front drive shaft, in particular the end into the transfer case are shot, hence clicking and crunching noises.

I have been trying to locate info on where to aquire these c.v. joints but so far I can only get the complete shaft either 2nd hand or new.

If anyone has any ideas or knowledge in this area it would be greatly appreciated.

cmohr · **Posted:** Thu May 28, 2009 9:06 pm

Probably that end that had the hole in the boot????? Cant remember.

I can check with my people as to if they can fix it, I remember Fros had that happen to his, one end or the other no good, possibly if his was the other end, maybe, get his old drive shaft off him?????

Team J.a.G · **Posted:** Thu May 28, 2009 9:23 pm

[quote="cmohr"]Probably that end that had the hole in the boot????? Cant remember.quote]

No...Other end closest to the Transfer Case, however C.V.'s on both ends are cactus :!:

Glend · **Posted:** Thu May 28, 2009 9:50 pm

Maybe this diagram will help sort it out.

http://www.jeep4x4center.com/jeep-axle- ... rty-kj.htm

Team J.a.G · **Posted:** Tue Jun 02, 2009 3:18 am

Well I think I'm a bit closer to getting replacement C.V. joints which will give me a 4wd again...hopefully for the up coming week-end.

Danny (mechanic) has had Gibson (Truck Parts) tracking down an appropriate CV that would suit the kj drive shaft and connections. It seems they have come up with something they believe will "fit the bill" 100%. The test will be tomorrow when it arrives. Fingers crossed :shock:

ed. · **Posted:** Thu Jun 04, 2009 3:49 am

I had the CV boot tear when I was 4WDing and so pulled it out of 4WD and got towed back out :lol:

I ended up paying 1k fitted for a 2nd hand CV + shaft as the new CV's are so expensive from jeep.

Be good if you could find an alternative

Glend · **Posted:** Thu Jun 04, 2009 4:36 am

Here is one alternative that might be a bit cheaper (about $234 USD).

http://www.jeep4x4center.com/jeep-axle- ... rty-kj.htm

There is also JBAs replacements (from $150 USD):

http://jeepinbyal.com/cat-Front_Drive_A ... ts-21.aspx

:wink:

pipeliner · **Posted:** Thu Jun 04, 2009 6:06 pm

Greg, I'm confused. Are you talking about one of the CV joints in the left and right driveshafts, or a universal joint in the driveshaft from the transfer box to the front diff?

Team J.a.G · **Posted:** Mon Jun 08, 2009 4:59 am

pipeliner wrote:

or a universal joint in the driveshaft from the transfer box to the front diff?

Chris
On the "driveshaft from the transfer box to the front diff" there is a movable joint at each end of the shaft. mechanics and the spare parts people have been refering to them as CV joints yet on the main drive to the rear diff they refer to the as "universal joints".

Perfomed well over the week-end though.

But now I have a missing front L/H guard due a big boulder that jumped out of a creek bed and bit me :roll:

G'ME MUD · **Joined:** Tue Jul 17, 2007 7:55 pm **Posts:** 370

Got to watch for those jumping rocks, they will come from anywhere. Is it the whole guard or just the flare.
I had a fun weekend doing night shift.... anyway off for a couple of days now so will head to mackay Wed and back Thursday arvo.

Transfer Case

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