While driving home yesterday my transfer case fell out. Just recently had a never one put in and of course it is damaged from hitting the pavement but I can't figure out what would've made the studs all break? It went together flush on the trans and from what I thought was tightened properly but I guess I was wrong. My question is: is it worth trying to find the right sized nuts and studs and fix it ( assuming nothing else is messed up)

 

The nuts were probably under torqued. Those are not self locking nuts, they just have a captive conical washer that acts as a locking device when torqued down. So if they aren't torqued down correctly at install they probably would back off and eject your TC out the **** end of your Heep.

I wouldn't put money into a TC that took a dive. Look around on Craigslist or go to a junk yard and see if they have one with some sort of warranty.

 

But that wouldn't be the reason the studs broke would it? If they were just under torqued wouldn't they have just backed themselves off?

 

If they got loose and transfer case started shifting back and forth its ver possible to sheer them of same thing will happen if wheel lugs are not tightened. What year are you driving.?

 

No warning sounds that someting was wrong?

 

I had a progressively bad vibration and noise on my way home the day before. Got home and looked at the driveline and where the front driveshaft connects to the tcase the part between the two u joints inside was broken. I took the front shaft out and no more noise or vibration. Next day sounded like my rear driveshaft fell out so I quickly stopped to find the transfer case laying in the road under the jeep.

It's a 94 cherokee. I just put a 231 on it

 

Other than the studs this was the only other real damage. I can replace the tailcone I guess you would call it and either rtv or a gasket to properly seal it. Correct?

 

Post a pic of the input gear and front of transfercase.

What donor vehicle gave up the 231?

 

Inspect the transfer case to transmission adaptor for damage around the TC mount holes. Cracks around the holes will be cause to replace the adaptor. Expensive part.

The TC studs can be bought at a hardware store. You'll need hardened studs, 2" long, 3/8-16 x 3/8-24. When putting the new studs in the TC, ensure there is 1 1/4" of the stud protruding above the TC mount flange. If a stud turns into the TC too easily, use red thread locker on the TC end of the stud.

The proper nuts can (maybe) bought from the dealer. The dealer studs are too short (I bought some but didn't use them).

Nut part number is J4006681.

 

This is the only picture in my phone right now. Back of the tranny. The shaft isn't knocked up or anything but the top is slightly. You can see in the picture

 

Was new case exact same as old ? Did drive shaft slip in easy no forcing required ? Same drive shaft as b4 ?

 

That happened to me in Moab, didn't fall out through but it was ready to. I never even took the tcase out... It never left the jeep after being put in on the assembly line. Broke 4 studs.

 

I had a 242 but went to 231 everything went together fine. I used the original driveshafts from my jeep. The tcase came from a 93 I believe

 

Transfer case slid all the way flush to back of tranny b4 tightening bolts ?

 

See this mark all way around don't look right to me looks like it didn't seat properly ?