‘66 Cj5 Tuxedo Build.

Donny, post #51 he says he just went with the original factory basic cj5 bumper, and not the chrome Tux bumper.

 

while trying to figure out what’s making the tapping vibrating sound coming from the transfer case area, I hopped under to see if anything was loose. transfer case was practically laying on the skid plate. swapped that out tightened it up. dramatically smoother and less vibration. Still getting a tapping sound.

 

The mount you replaced is not correct for your Jeep. That is a 4 cyl biscuit mount that is intended to fit directly between the T/C housing mount tab and the crossmember.
The V6 Jeeps use the offset bracket you have, and use smaller bushings. It looks like the bolt of your new mount might be touching the underside of transfer case front output housing, maybe causing the noise you have.
The idea is to have the trans/TC mounted in rubber isolators that also limit twisting as the driveline loads under power.
The V6 model transfer cases often have a side mount from inside the frame rail to the side of the case. For a few years, they used a 4 cyl engine mount as a isolator up inside the frame channel.
-Donny

 

well I came home to this today along with a floor covered in oil. Looks like the holes from the inside? I think this is where my knocking sounds coming from? Anyways I feel like a d18 rebuild is outside my wheelhouse. What would be a fair price for a rebuild? Any recommendations on shops in northern Nevada?

 

The dana 18 is actually a simple rebuild and there are rebuild kits at novak and herm the overdrive guy. It is relatively very simple compared to a tranny. You can download the instructions from Novak to judge for yourself.

The Novak Guide to Rebuilding the Jeep / IH Dana 18 Transfer Case

Also you may post a want to buy ad here and see if anyone has a dana 18 for sale.

 

another question, if the t86 had gears switched out to the t90 gears, would that cause any issues with the D18?

 

Brian.... I have a rebuilt Dana -18.... right now for sale on the early CJ-5 classifieds... at a very fair price $450 ..... this might be just the ticket for your needs..

 

Your leak looks like something was drifting around in the transfer case and got caught by a moving part and ended up punching the debris into the oil pan. That might not be a fatal problem, but you need to find out what did that, and why. A broken tooth from a gear is the most likely culprit. Drain the gear oil and pull the pan to see if anything looks out of place.
-Donny

 

Brian's transfer case is a single-stick version. You transfer case can be converted to single stick, but its pretty much a complete teardown and build back up to make it work.
-Donny

 

I was looking at that. And we’re a couple states away.

you think I’ll be able to just pull the pan off and find the issue without pulling out the t-case?

 

Considering where the pan got punched from inside, I think you can figure out what happened. I'm not promising you won't have to pull the transfer case in the end, but you'll likely find what caused the damage, probably laying in the bottom of the pan. The pan opening gives a large view of much of the internals, and you've got to repair/replace the pan anyway.
You should have a "big" hole D18, meaning you might not have to remove the transmission with it.
-Donny

 

the rebuilt transfer case is duel stick.... why can't Brian just bolt it right onto his present transmission....? no modifications needed except new rubber boots on top of the duel stick.....

 

BOOM GOES THE GEAR BOX

 

Eh, that'll buff out.

 

Kind of what I was expecting, but I thought there would be a couple more bigger bits. A couple replacement gears needed, but not fatal. I'm curious if those are original Dana gears or aftermarket? Usually, something else causes the gear to break a tooth to begin the carnage.
Yes, the transfer case needs to come out for this repair.
-Donny

 

Oof. BTDT, although mine jammed between the gear sets and broke the case in half while rolling down the highway. Twice. So I guess consider yourself lucky you still have a case to work with.

 

Bummer! For whatever it's worth, I had next to no real mechanical experience when I decided to partially refurbish my D18 and T86 (with T90 gears). With metalshapers videos and the FSM/Novak's site plus the great advice of the guys/gals on here I was able to get through that part of my build. If you take things slowly and go step by step you might just surprise yourself and learn a thing or two along the way.

 

Being a big bore like you said I should be able to just unbolt from the transmission after I drop the drive lines and speedo cable?

 

In theory, you can remove the transfer case leaving the transmission in the Jeep, but in practice, you might get lucky. I have done this successfully, but I have also had the transmission rear bearing adapter/carrier come loose, allowing the mainshaft to shift rearward, dumping all the input shaft roller bearings to drop to the bottom of the case. When this happens, the transmission has to come out anyway.
I usually drop the transmission and transfer case as a unit to service them.
-Donny