Topic: YJ t-case into TJ dilema

[stan98tj]

Hey guys,
Buddy of mine with a 97tj 4.0 5spd was having some t-case issues and decided to swap out. A friend of ours offered him a free t-case out of a 91 YJ 5spd. We got it all mounted but then noticed the mounts into the fwd yoke was different. Does anyone know if an adapter of sorts is available for a TJ double cardan into a YJ front yoke?
Here are some pics to show the issues

the YJ case with the TJ shaft:


The TJ case:

[FourbangerYJ]

How about swapping yokes from one to another? Splines should be the same.

[Jeffy]

Yup that's what I'd do.  The YJ does not use a CV yoke.  Different yokes all together.  Takes like 2 minutes with an impact wrench.

[dwtaylorpdx]

YJ case is slip yoke, Isn't the TJ fixed? You could always put the YJ guts in the TJ case if the case is still usable.

Dave

[stan98tj]

Yup that's what I'd do.  The YJ does not use a CV yoke.  Different yokes all together.  Takes like 2 minutes with an impact wrench.

essentially open the case. He wasn't sure if the yokes were the problem to begin with (on his t-case). I had suggested that but he wasn't sure if his were good or not.
A few questions:
Do you think there would be any type of adapter double cardan available for this?
Are there anymore differences we should be aware of? I did a quick search and apparently there's a vacuum line to the front diff on YJs?

[Jeffy]

essentially open the case. He wasn't sure if the yokes were the problem to begin with (on his t-case). I had suggested that but he wasn't sure if his were good or not.
A few questions:
Do you think there would be any type of adapter double cardan available for this?
Are there anymore differences we should be aware of? I did a quick search and apparently there's a vacuum line to the front diff on YJs?

Swap the shift fork assembly for the mode select.  That's the ratchety bit.  YJ's don't have a true neutral unlike TJ's. You don't have to do it though.  Other then that it's basically the same internals.  You can plug the hole for the vacuum switch.

The yokes are complete different CV's have a bolt that goes though the yoke and the strap part is on the CV.  You can't use a standard yoke for that as it will have threads and a lot of meat behind so you can't fit a bolt through there.  The only way to fix it would be to get the correct yoke.  It's like $50.  Oh and you do not have to replace the whole shaft, just the yoke.

[sharpxmen]

YJ t-case seals on the driveshaft slip yoke, TJ is still a slip yoke but the seal is on the shaft itself and the slip yoke is external. I have no idea if the d/s works from one to the other or you need to swap it.

the front output yoke can be replaced from the other t-case like others have suggested, take it off the old TJ one and isntall it on the YJ t-case, the spline count is the same. But looking at that picture - is the CV housing broken at the u-joint facing he t-case or is it some weird optical illusion i can't get my head around?

you can ignore the vaccum valve for the YJ quick disco actuator, it has no functionality for the t-case itself.

[stan98tj]

He can get his hands on a few YJ shafts for free to use as well as XJ shafts. Would they work? This would be to avoid having to take out the t-case again and then opening them and swapping out yokes.

[neale_rs]

You don't have to take out the shaft to swap yokes.  Just take off the nut that holds the yoke on the shaft.

[sharpxmen]

you don't have to take out the t-case or open it, just like he ^ said take the nut off (i think he meant to say t-case and not shaft)

[Jeffy]

Oh and you do not have to replace the whole shaft, just the yoke.

You don't have to take out the shaft to swap yokes.  Just take off the nut that holds the yoke on the shaft.

you don't have to take out the t-case or open it, just like he ^ said take the nut off (i think he meant to say t-case and not shaft)

 

[Bounty Hunter]

You should simply swap the front output yokes between the two t-cases.  Use an impact and a 1 1/8" socket.

The rear output is different between the two t-cases.  The TJ mainshaft is a little bit longer than the YJ so it may be a little too long unless used with a lift.  Use the YJ slipyoke on the rear output as it has a better range of travel before binding.

Don't worry about plugging anything on the vacuum ports, just leave the vacuum switch screwed into the t-case.

[stan98tj]

Swapped the yokes tonight. Buttoning it all up tomorrow and taking it for a spin.

[sharpxmen]

yeah, didn't read all the replies just the last one