When do you know to change your transfer case in a jeep?

Answer 1

Problem Transfer Kits Solve: When you lift a vehicle over 2 inches you change your drive line angles. This can cause unwanted vibrations. A transfer case drop kit lowers your cross member and helps restore your drive line angles closer to OE specifications.

This is an install guide (with horrible attempts at humor) for a transfer case drop kit on a Jeep. This is a beginner guide, those who are experts already know how to do this, we hope! This covers most aftermarket transfer case drop kits and works on the following vehicles;

1984 - 2001 Jeep Cherokee XJ

1993 - 1998 Jeep Grand Cherokee ZJ

PRE-INSTALLATION MEDITATION: Beginner Level - 10 minutes

Before you start your install you should meditate on these tips - Read and visualize you happily installing your new kit, gather the following items and tools if you have them (if not a local auto store can rent them to you sometimes at no cost): Welder, heavy duty floor jack, super sturdy jack stands, penetrating spray that works, and a good socket and wrench set (vice grips wouldn't be bad either). It might be helpful to have a second person or spotter with you and its nice to have someone to talk to!

DROPPING OF THE CROSS MEMBER: Novice Level - 30 minutes

A. Put the vehicle on a flat dry surface and use appropriate chocking tools for the tires. Don't forget to turn off the motor! Place the transmission in neutral and turn the shop or garage radio on (this step is optional).

B. Liberally spray penetrating lubricant all over the cross member bolts and studs and let sit for a while. How long is up to you but as long as it takes to eat a combo meal is good. Use a rag and wipe up any excess lubricant to prevent the wrench or socket from slipping.

C. Support the transfer case cross member with a transmission floor jack. The jack should be placed on the center of the cross member just below the transmission mount. Remove the 2 bolts, 2 nuts and 2 studs from each side of the cross member. PLEASE NOTE: some cross members have 4 bolts, some have 2 bolts and 2 studs. If yours has 4 bolts this installation will be a lot easier.

NOTE ** - a lot of people say they cannot put these kits on because the have studs instead of bolts coming from the cross member. The studs need to come out. This can be difficult and require a lot of penetrating spray. The easiest way to remove the studs is to weld a nut on there and wrench them off. The next easiest way is to use vice grips.Be careful and do not damage threads. You can always have a professional install this kit or get a buddy to help you.

INSTALLING THE TRANSFER CASE DROP KIT: Novice Level - 30 minutes

A. Slowly lower the cross member 1 1/8 inches or more (depending on the size of your transfer case drop kit) to allow enough room to install the new tube style or bar spacers. You need to be very careful when lowering the cross member as the weight of the transmission and transfer case assembly are on the jack. PLEASE NOTE - safety first and second and third.

B. Place the spacers (see photo for example of the spacers) supplied between the frame and cross member and be sure that all the mounting holes are lined up. You want to make sure that the the bolts will fit through the cross member and into the frame and that the spacers are not impeding access. This step is best with a buddy or you may be running back and forth to each side of the Jeep.

C. Slowly raise the jack up to firmly hold the spacers in place between the cross member and frame. This can be tricky as you don't want anything to shift. The best way to do this is to snug it up just enough so you can move the spacers around but they stay in place once you have them where you want them to be.

D. Using the new bolts (if supplied) or the stock bolts attach a washer onto the bolt and apply thread locker to the threads of the bolt. Insert the new bolt and washer assembly through the stock holes on the cross member and through the transfer case drop kit spacers and torque to 35 foot lbs. Carefully lower and remove the transmission jack and set aside.

POST INSTALLATION TIPS: Beginner 10 Minutes

A. Drive the vehicle for a short distance return to a flat level surface and check the tightness of the bolts and if the cross member has shifted. If there are any problems re-install the kit or remove. I would go to the local gas station and get a drink your probably thirsty after all that.

B. Drive the vehicle for 50 miles and re-torque all bolts. Pat yourself on the back.