Transfer case and front axle

[Fraken jeep]

I'm working on a jeep I traded a buddy for and it has what appears to be a dana 18 Transfer Case with a dana 25 front axle. I am wondering what the best way to hook this up is since the yoke in the axle is of a bigger series than the drive shaft from the Transfer Case .

 

[Purple77CJ7]

A local driveline shop should be able to build you a new driveshaft with different ends. All so Tom Woods builds custom shafts. There are several of us here that have used Tom Woods, does good work. Either place should be able to figure out what yokes you have and driveshaft length.

Tom Wood's Custom Drive Shafts - Tom Woods Custom Drive Shafts Custom Driveshafts Specialist

 

[Fraken jeep]

is this the only way to go or is this just the best route to go in the long run? I was looking for more of a solution that I could just go to napa and pick up or something of that nature.

 

[Purple77CJ7]

You could pull the yokes off of the diff and Transfer Case and take them in to get new crosses. But if they are different on the shaft, you will have to take it to a shop for new yokes on the drive shaft. The the shaft length may need to be changed, also. A local shop should be able to fix you up. I wouldn't think it would cost all that much.

 

[73CJ]

I suspect somebody may have puta wrong yoke on over the years.

Both should be the same size. Start measuring the caps and yoke splines. Then compare them to the stock specs.

 

[hagar]

If the D18 came out of a V6 factory application, the front driveshaft yokes and u-joints are smaller, the 5-248X series.
You could change the yoke at the Transfer Case to the larger 5-153X type, which would be the std u-joint used on all CJs from 1941-1986.