88 YJ-CJ Transfer Case

Transfer Case Shift Rod

In one of my smartest decisions ever, I decided to finalize the transfer case shifter rod on the bench (and not under the Jeep!).  I bolted the shifter to the transfer case with temporary spacers to get the same distance as the Novak adapter.  

Luckily, I had several shifter rods to choose from.  I needed one with an offset as shown below.  And I needed to modify it for more adjustment length.  I did it on the lathe since I've got it.  

Test Fit:

I'm happy enough with the alignment.  The bushings have some "give" to them.

New green bushing installed:

I couldn't get all the shift positions...the shifter arm bottomed out on the bracket, which limited travel.    

I ground away part of the bracket to gain back the clearance needed.  All shift positions are now available.

Transfer Case Seals

Two new seals were installed, and the Novak adapter was installed onto the transmission.

Transfer Case Installation:

Then the transfer case was installed:

It was like a jig saw puzzle.  I had to remove the crossmember and transmission mount:

This location was incredibly tight.  You can also see the shifter rod:

You can see the shifter rod here:

It shifts very easily:

The transfer case vent hose was also installed.  I still need to clamp it to the firewall.

Front Driveshaft Length:

I measured for driveshafts, but nothing that I had in my parts stash would work:

Two front driveshafts were the correct length, but they were 1330 u-joints (I need 1310).

My other front driveshaft had the correct 1310 u-joints, but was 6" too short.

Here are the two 1330 driveshafts.  The (too short) 1310 driveshaft got installed into the Jeep to check clearance.

Rear Driveshaft Length:

My two rear driveshafts are both 1-2" too short, but they do have the correct 1310 u-joints.

At some point, I'll get both a front and rear driveshaft modified to fit.

Both too short:

Front Driveshaft Clearance:

I temporarily installed the 1310 front driveshaft to checked for clearance, as it looked like it would be tight to the both the body and crossmember.  It is tight, but I should be good for clearance: