TCase Advice needed on Transmission and Transfer Case

[Sawjaws]

Hey fellow jeep people. I got myself a 1978 CJ5 that was a full on mudder by the people I purchased it from. They said the clutch was out, but everything else is good. I have the Transmission and Transfer Case out (still mated) and am cleaning the mud off of it before installing the new throw out/release bearing and fork. In cleaning it up and doing a little checking, I noticed there are holes over the shift rods where the detent balls and springs are supposed to be removed which were obviously caked in mud and are supposed to have caps in the holes. I don't even know if there are threads there anymore or if rust has defiled them. The question is... how imperative is it to replace these caps and what is the likelihood I have mud in my Transfer Case ? The shift rods do move okay. A bit stiff, but not stuck or anything.

Also, given this situation, do I bite the bullet and pull them apart and clean, inspect everything and paint the Transmission and Transfer Case , thus squelching my excitement for getting the jeep running and moving? Mind you, it is not a pristine vehicle and will likely just be used for hunting trips.

Any and all advice is appreciated. I am leaning heavily toward just changing gear oil on both and slapping it back together and potentially doing a full refurb on the vehicle later on.

 

[Manic Mechanic]

I'd separate them. Pressure wash it. Paint it. Change the fluid and then slap it back together and in and the H E double hockey sticks out of it.

 

[KRUPP]

It’d be pretty difficult for mud to infiltrate the case thru the shift rail passages.
It’s my O.C.D., but I would absolutely have to divorce them, drain oil, pull cover plates and take a look inside.
Then, go from there.

There should be some press-fit caps in the holes to access the detent balls and spring. They’re like mini freeze plugs.

 

[Belizean]

^^^^^^. X2. It’s already out. If it was installed and you were driving it probably not so much.

 

[Sawjaws]

So here is what I'm referencing. Not the side holes, the top holes where the detent balls would come out if you pulled the shift rods. You can see the rods down there moving back and forth when you shift it.

I think I can get new caps on eBay. Are they a must have?

 

[Sawjaws]

Whilst we're on the subject... What is this and should it spin freely around whatever is underneath it? Because it does.

 

[KRUPP]

Yikes!
Take apart. Drain. Clean. Repair. Reseal. Repaint.

That 2nd pic is a breather and it should spin free. It’s better to replace that thing with a barbed x threaded fitting with a hose to a higher point, like up on you firewall.

 

[Belizean]

Even though my Transfer Case was I figured, not very well worked in it’s life because of not a whole lot of use, and no mud use like yours, you can see my shift rod was still a little corroded. I wanted some lower gears so I rebuilt mine, they give you one rod in the rebuild kit, I ended up replacing the other. Hoping I would never have to remove and take back apart.

 

[Jeep Soup]

My Nickel.95
If those Plugs are Missing,
Someone has been Inside that Transfer Case before. So as recommended, at least get a gasket set, drain, and do a Full Inspection.
Your saying that it was a Mud Bog Racer, it has had a HARD USE previous life.

Plus you get to see the Innards of what 99% of the Population never gets to See ....

 

[Sawjaws]

Thanks all for the input. Although I'm excited to get it moving, I do think I will unmate and inspect them, clean them up and paint them. Looking into the gears from the Transmission shift lever, everything looks very clean and I don't expect to see major damage, but It's best to do it s right as possible while I have it out. I will get just gaskets set as you recommended Jeep Soup

I do have plenty of other work while I wait for paint, gaskets and new caps, so there's that.

I appreciate all your help! Looks like the store brush wheel and rust remover is coming out this weekend!

 

[Belizean]

I didn’t even bother to paint mine. Usually enough oil around to keep it rust free, unless you like mud. I’m not a fan of mud.

 

[KRUPP]

I believe you have a Dana 20 Transfer Case there.

While you have it apart, it's an opportunity to do some upgrades, as well as the maintenance...

-The Dana 20 Transfer Case on my early Bronco is a bit different than the Jeep version. It has the ability to use actual bolts in the access holes for the shift rails which ride against the springs and balls to adjust the tension on the shift rails. The Jeep Dana 20 doesn't have this ability, but you can upgrade to stiffer springs, or some people even shim the original springs with little washers to achieve more tension.

-While this Transfer Case is a tough little guy, they do experience issues with the rear output, especially with steeper rear driveshaft angles and rear axle wrap from off road abuse. There are upgrades available for a larger output shaft. I'd look into that as an option if your output is wobbly or the shaft or bearings are worn.



-Another great upgrade to do, while the case is apart, is a Twin Shifter kit. Great option to have, in my opinion.