Jeep WJ front drive shaft converion tips?

[golfinWJ]

Picking up the front drive shaft tomorrow from the junk yard, the transfer case yoke arrived today so the plan is to swap out my front drive shaft this weekend...just wondering if there is anything I should know before doing so?

[Mr.WJ]

It should be straightforward.

Have handy:
1 1/8" socket, I have one.
Breaker bar
2/3 Jaw Puller, rent from Advanced
8mm socket or wrench for the d.s. bolts.
Extra ATF to refill what leaks out the transfer case.
Fill plug hex key
Double Cardon yoke bolts, 4x that go from the yoke to the shaft. Can't get them anywhere but the dealer. (Or online.)
Reuse front axle hardware strap kit.

Put the transfer case in 4low so it'll keep the yoke front spinning while trying to get the nut off. Make sure the rubber gear shaped gasket goes back on. Slide the new yoke on and torque to "90-130 ft-lbs" according to the FSM. I put mine about 120 ft-lbs.

Inspect the DC joint and make it isn't sloppy, I had mine rebuilt before I put it on. Also if you have to really pull on the shaft to get it to reach, it is going to be too short. (Learned that the hard way when mine only had about 3/4" of slip left before it was going to come apart.)

I'm free all Thursday.

[golfinWJ]

Not too worried about it fitting since the new shaft is already from a jeep like mine with the same motor, transmission, and same transfer case. 2 questions though: 1- where did you find the torque specs for putting the new shaft on and 2, how much atf should I expect to lose during installation?

[Mr.WJ]

I didn't think the I6's came with a front double cardon from the factory, I could be wrong.

- Those torque numbers are from the 04 WJ Factory Service Manual.
- Maybe a 1/4 quart or so. However, while you are there though, IF you haven't done the transfer case fluid recently, might as well do it. The total capacity is about 1.5 quarts. I've found my t-case likes to go back into 2wd easier with fresh fluid.

[golfinWJ]

Does it take a specific type of Fluid, and if so where is the best place to get it?

[Mr.WJ]

Plain and Simple ATF+4, cheapest would be Walmart.

http://wjjeeps.com/service/maintenance_wj.htm#TCASE

[golfinWJ]

Ok thanks. Might as well perform a little maintenance on the ol' girl while I'm at it.

[Mr.WJ]

I'd do it, like I said fresh fluid made it less of a bitch to get out of 4wd.

[golfinWJ]

Another quick question...do the bolts that go in the yoke section have torque specs as well or does it matter?

[Mr.WJ]

I'm sure there are somewhere, you'll feel a difference when it get tight that is about where I stop. FSM says 20 ft-lbs at the transfer case yoke.

[golfinWJ]

Hey i sent you a PM

[Mr.WJ]

Did you get the D.S. in and good to go?

[golfinWJ]

Yeah it went in fine...just took me a while doing it my self. But i forgot to remove the dust cover from the old yoke and put it on the new one so now I have to remove the shaft again and put that back on. While it's off I'm going to go ahead and replace the t-case seal with a new one.

[Mr.WJ]

You don't *need* it per say. I am surprised it didn't come with a dust shield. Mine did.

I have a an extra Timken 242 t-case seal if you still need one. $5

Any vibrations?

[golfinWJ]

Nope, no vibes that I can feel and I already picked up the seal from advanced auto yesterday. It inst leaking anything at the moment so I might just keep it with me in case I need it later...haven't decided yet.