Transfer Case during Clutch Replacement

[capejeep99]

My vehicle is 1999 XJ 4.0, 5 speed manual with 4 wheel drive. I’m preparing to replace the clutch (I’ve not done this before). Is there anything I need to do regarding the 4wheel drive transfer case, or does the clutch replacement not affect the transfer case?
Thanks!

 

[ChillyB]

Clutch change won't require anything be done to the transfer case. However, if there is anything you think you should do while it's out then now it the time. Chains are a wear item and will stretch. They last a long time but your Jeep is 26 yr old. If you hardly use 4WD it may be fine. If you use 4WD a lot it might be a good time to at least replace the chain.

I am doing a 4WD conversion to an XJ. I'll give the transfer case a full rebuild and also put on a slip yoke eliminator before I install. I'm at a position where I can afford some extravigances and have the space, tools and time to do most work like this. At other moments in my life I would run what I had if it wasn't causing problems yet because I had not the disposable income, time, tools or space. If this is your daily driver then you need to get back on the road ASAP. Bare minimum time and expense.

 

[capejeep99]

Thanks very much for answering my question, ChillyB. Very helpful! Fortunately, the jeep is not my daily driver.... just trying to make it last long as I can. I don't really use 4WD all that much, but nice to have when needed. When I do use it, I can smell what smell's like burning oil.... so probably some maintenance is needed. I bought this jeep new and don't know that the transfer case ever had any maintenance done to it. So I may take a look at it and see if there's any attention I should give it. I'm not all that experienced in working on my Jeep but slowly have been taking on some projects with it (that sort of put me out of my comfort zone).... changing the clutch being just that.... will see how it all goes. But thanks again for the help.

 

[ChillyB]

Easy diagnosis is to get a clean drain pan. AutoZone has specials on oil change kits where you get oil, filter, a cheap black drain pain, and maybe a roll of rags. Also maybe get a paint fikter, which are paper cones with a fine screen in bottom (optional). Drain the transmission case from here:


It takes a 10mm hex bit or Allen wrench. Check your drained fluid for metallic debris that may look like fine glitter. There is a magnet inside the case so you may not see much even if it's wearing metal. But for sure if you see it then a rebuild is justified. If you dont get much fluid then also likely time for a rebuild. I think it takes 1.5-2 quarts but you should check. Memory isn't great. You should not have ANY detectable lateral slop in the output shafts. You will have some rotational slack. I don't know what is normal. Mine seems loose and I'll install a new chain and compare and measure in a way that can give you an idea of what the replacement did for mine.

If you have leaks then at least you have oil. If no leaks then either a good sign (no leaks) or a bad sign (empty). If you have leaks or an empty case then If rebuild. You kept it this long, if you intend to keep longer then give the old girl some love

Refill here with Dextron III (I think) tranny fluid, not gear lube.

 

[ChillyB]

Would you look at that. 2.62 pints.

 

[lawsoncl]

Pro tip - get the fill plug out first, then drain it. It really sucks to drain it, then discover the fill plug won't come out.

 

[capejeep99]

Rather than start a new thread I'll continue with this one.
I'm currently spraying PB Blaster on as many bolts as I can find to facilitate removing the housing bolts to replace the clutch. My understanding is there are 2 E12 bolts somewhere on top of the housing. I can't really see them but is there anyway to see them from looking in from under the hood? Or any ideas how to locate them and spray them from underneath?
Thanks.

 

[lawsoncl]

They're hard to lay eyes on without unbolting the cross member and lowering the xfer case. Yes, they are E12, not hex, and it's best to break them loose before undoing the bolts on the sides. You'll need mulitple extensions to reach them.