It's the 231.

Drained the transfer case fluid (first time in about 25k miles) and it was BLACK with metal particles.

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Elmer
2005 Jeep KJ Renegade

Yeah black fluid and metal particals is not good.Why I always changed,and still do change,my t-case fluid every 6000 miles.Less then $10 so why not,but know at least I have a site-tube to see the condition and level by just looking under my Jeep.

What would you suggest I do?

A new case is out of the question as I just can't afford it. I found a 231 at the local salvage yard for $100. It's on a 2006 Liberty that was involved in a front-end collision. Looked to be in better (cosmetic) condition that mine, do you think it's worth picking up?

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Elmer
2005 Jeep KJ Renegade

Go look at the KJ it came out of,as long as the cradle was not pushed back,IE forced the front driveshaft into the t-case,I would snatch it up for $100.

Not a hard swap at all.The hardest part is you must support the trans as the rear crossmember must be removed and the rear mount taken off to get the bottom 2 nuts.

Great. Thanks for the help man.

The salvage yard does not allow jacks to be brought in (they lift the cars for you with a forklift and let you do your thing), so what else could I use to support the transmission while removing the transfer case? Would tossing an upside down 5 gallon bucket under it suffice? All I'm concerned about is getting the transfer case out without messing it up.

As soon as I get a transfer case installed that works properly, you can bet I'll change the fluid every time I change the oil. For $10, why not.

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Elmer
2005 Jeep KJ Renegade

Would it be easier to pull the tranny+transfer case as a whole rather than pulling just the transfer case?

Keep in mind I'll be in a junkyard that will more than likely be muddy from recent rain, and I'll be limited on supplies.

Just looking for the easiest way to safely remove the TC from this junked out Liberty.

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Elmer
2005 Jeep KJ Renegade

If your just removing it at the junkyard I'd just let the trans/t-case drop when taking the rear crossmember off but that's me and I know what's going to happen.Be very careful as it will drop pretty far before you max out the engine mounts and will make getting the 2 top nuts much easier.Using a 5 gallon bucket would make things alot safer and I'd advise at least doing that for safety as your dealing with alot of weight and can injure yourself pretty easily.Just make sure everything is disconnected(driveshafts and linkage) before dropping the crossmember.The t-case is about 75lbs.

This will (obviously) be the first time I've removed a transfer case, so it will probably end up dropping.

Correct me if I'm wrong on the order of any of this:

-Lift the Liberty
-Remove skid plate
-Drain transfer case fluid
-Disconnect driveshafts, vent hose, shifter linkage, and speedo cable? (I'm not sure where these are located on the TC, but is it safe to assume I just disconnect all wires/tubes connecting to it? Do any of these require tools or can they all be disconnected by hand?)
-Place 5 gallon bucket under transmission
-Drop crossmember (what is entailed here? I assume removing a few bolts is all?)
-Hopefully the tranny/t-case combo will drop down onto the bucket...?
-Remove six 9/16 nuts connecting transfer case to tranny
-Pull transfer case away from tranny and it should drop fully

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Elmer
2005 Jeep KJ Renegade

Pretty much.

The nuts will be 15mm,a moon wrench will work best and a shorty/stubby wrench for the top nuts.The crossmember just has 6-8 bolts(3 or 4 per side) and then the rear mount cross bolt.

Awesome. Can't thank you enough for the help.

I think I'll test out my current wrench lineup on my transfer case tomorrow just to be sure I can reach all the nuts with what I have. If I run into issues, I'll go pick up a 15mm moon wrench.

I'll be sure to document the process at the junk yard with pictures and keep this thread updated. Heading to the junk yard at 8am EST Saturday morning. Hopefully I won't have any trouble, but you can be sure I'll come straight here if I do

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Elmer
2005 Jeep KJ Renegade

Home depot has a terrible selection of wrenches.

I guess I'll try Lowes tomorrow morning for a 15mm ratcheting stubby.

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Elmer
2005 Jeep KJ Renegade

Well... I was able to pull the transfer case successfully. Took about 2.5 hours, and ended up covered in grease, but was worth it. The last two nuts were stripped, but luckily was able to force a 9/16" box wrench on them and work them off. Will post pictures later on.

The t-case seems to be in decent condition, albeit a little dirty. Will clean it with brake cleaner and then give it a couple good coatings of engine paint. Will post before/after pictures later as well.

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Elmer
2005 Jeep KJ Renegade

Just a tip................

Don't paint the t-case,it's alloy and paint will only trap heat and the bare case is part of the cooling system along with the mini fluid cooler inside.