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Transfer case replacement gone wrong.

Transfer case replacement gone wrong.
Posts
99
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Location
Gulf Coast, FL
Vehicle(s)
1981 CJ7, 258 I6, T5
1986 IRoc, 383, TH350
Hey guys,

It's been a while. Between work, deployments, and life, the Jeep took a back seat. I wanted to replace my Transfer Case ... I ended up getting a full setup. This lead to me taking off the grill. After that you may as well take off the fenders. Well only a few more bolts to take off the tub...

CVkimNE.webp Here I am now.

I plan to take the frame off the axles next and paint it. POR-15 seems to be the answer I get most. The frame is rot free, EXCEPT in the back left corner. There is ~2'' by 1/2'' hole in the lower inside of the frame. I count my self lucky! I also may cut some holes in the back of the frame where it dips down to prevent this in the future. I will also dump about 1/2 a bottle of oil down each side and rotate the frame to coat the inside some.

I do have a question. While I am at it I may as well replace the Transmission cross-member. It has been a while and I can't seem to find the good 1'' drop. Anyone know a good site to pick one up?
 
Pouring oil inside of your frame is a decision that I think you will regret. Everywhere you go, you will be leaving puddles of oil for a long time, and it does not work as well as you think. Give this a look, Eastwood Internal Frame Coating Black 14oz Aerosol. I have used it, and it works great.
There are a lot of places that sell universal crossmembers, Summit, JEGS, etc., or just make your own. Do a Google search and look at the images. Lots of ideas there.
 
If I were to go that route I would seal the holes in the frame and put plugs at the low spots.
 
No, on the oil idea.
Pressure wash and flush. Park at an angle to drain/dry.
Remember-oil floats on top of water.....
LG
 
I would also nix the motor oil in the frame idea. If you're going to all that trouble, there are a number of other (and better) products to use: Boiled linseed oi, POR15, etc. You could even get some undercoating sprayed into it. Since it will be a bare frame, take it to Ziebart or any of the remaining places that does rustproofing and get a quote. That way they'll have the mess on their concrete. And you won't.

Crossmember: Throttle Down Kustoms

1976 to 1979 Skid Plates | Custom Jeep Skid Plates
1980 to 1986 Skid Plates | Custom Jeep Skid Plates

Jeremy will make you one up however you want. He made mine (76 CJ5 ) without the Transmission mounting holes so I could align my drive train perfect.
 
've wondered several times about doing this. Once a frame is all set up and ready to go, I wonder what construction foam inside the tubes would do. It seems sorta water proof, is relatively light and would dampen noise. Probably a crazy idea, I wonder if anybody has done it?
 
IMO-Foam wont' let the frame 'breathe' and would be a very serious health hazard if you had to weld on it.
LG
 
've wondered several times about doing this. Once a frame is all set up and ready to go, I wonder what construction foam inside the tubes would do. It seems sorta water proof, is relatively light and would dampen noise. Probably a crazy idea, I wonder if anybody has done it?

My brother picked up a 1989 Yj a guy did that to on the back part of the frame well what you could call what's left of the frame. It did go well for them that's why he got it for so cheap. He ended up putting a new frame under it
 
Not surprised it didn't work on an old nasty frame and Lumpy's right, welding on it wouldn't be a good idea. But if the frame were new and completely welded up and finished .... yeah I know somebody would weld something on it eventually.
 

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