Transfer Case Drop issues

[XJ take 2]

Hey guys, i have been having a hard time and need some advice. I was trying to do the transfer case drop that came with my lift, but due to a series of sad events my situation is as follows. Out of the 4 bolts and studs, both studs just pop out threads and all and are now rolling in the frame, one bolt came out fine and isnt an issue and the other bolt broke off and has been drilled out in an attempt to remove it, so now i have 3 huge holes and one working thread, any ideas? im at wits end with it and am honestly starting to get really frustrated

[4x4Dalton]

Can you try tappin the 3 holes and making new thread in them for larger bolts? Im new at the whole lift aspect of it all.

[SemperFi1371]

Helicoil!!! I had a similar issue on an old HEMI, I stripped out a few head bolts, The engine had been sitting in a swamp for at least 24 years and all the bolts were cold/rust welded, well all the ones that hadn't disintegrated! I tried tapping to no avail and picked up a couple heli-coil (or Keysert, Fulltorque, ezlok, Timecert, etc. to name a few brand names.) kits (Amazon has them cheap, eBay too) and it worked perfectly! You can also use a high-quality epoxy if you wish to use a stud again, though I usually just weld them. I have used many different manufacturers products for thread & stud repair in my line of work, Plumbing, and they are all pretty much the same. I have no recommendation of one over another, I use Fastenal for most of my work & automotive applications, but I get a deal through work. I have included a few websites of the different manufacturers of these kits. As for epoxy, any metal fab style should work or even JB Weld (fill the hole, inset stud & allow to cure.) Best of luck to you!

http://www.emhart.com/

http://www.timesert.com/html/install.html

http://fulltorque.com/

http://www.permatex.com/products/Automotive/thread_compounds/thread_repair/Permatex_Stripped_Thread_Repair.htm

http://www.newmantools.com/recoil1.htm

http://www.afsrecoil.net/en/Products/Keysert.html

12.9ml Syringe Form-A-Thread Stripped Thread Repair Kit | Fastenal.com

[4.3LXJ]

I take it you mean the nuts in the frame are no longer there? Your local fastener shop, like Fastenal, have a thing called nutserts. It is like a pop rivet with threads in the center and come in various sizes. So what size you get will be dictated by the hole size in the frame. They are not hard to put in and will be like stock when you are done.

[modestmar00xj]

good thread man! right now im having the same problem!

[XJ take 2]

well i found a solution and its going to cost me big time, because the holes are huge and in the frame they cant be threaded, nothing there to do that with, also fasteners or heli coils wont work because the holes are too big for them and no one around here sells ones that would work. the only solution is to get a nut up in there and weld it in, i dont have the time or the equipment to do that with so i had to take it to a shop :(, 100 bucks because i destroyed those holes, but hopefully this will be the last thing on my lift beside the steering stabilizer

[bluedragon436]

I was going to say I had seen a similar issue on a guys build the other day on CF... I am really hoping I don't have these same issues with mine when I do my lift... I actually think I am just going to install the lift without the TC drop and see if I have the vibes... if I do then I'll take the chance of having these same issues.. (really hope not, as I can't afford a shop right now)..

[XJ take 2]

i went up 4.5 inches and the vibes weren't unbearable but they were pretty noticeable during acceleration even though what i had to do sucks, i highly recommend the Tcase drop when i was messing with it i saw my drive shafts go back to normal, its a good feeling

[bluedragon436]

I wish I could find myself a 5spd. XJ in the JY so I could pull the crossmember off of it... as that would give me a fairly decent drop, and wouldn't have to worry about taking the studs out.... but it's all good... already got the TC drop.. might as well make use of it.. and just hope and pray that it goes smoothly!!

[bluedragon436]

Alright... never mind on the TC drop... just found a kick a$$ deal on a SYE kit, that will allow me to make use of a stock front DS... so that way I only have to keep a spare DS of one kind and it will work on either position in case of need on the trail... so I guess I will just put off the install of my lift just a tad bit longer to get that better option/upgrade!!

[LizardRunner]

Yep, SYE is the way to go. I have talked with many who have the 4.5 lift and all have recomended me to get the SYE instead of doing the drop.

[XJ take 2]

SYE kits are cool but expensive, and they dont come with the kit that i got, but the transfer case drop did come with the kit, and after i had it installed properly, all my drive line vibes are gone and im running smooth again

[LizardRunner]

awesome on getting that in right! Glad your wheeling again

[bluedragon436]

This is the deal I have been looking at getting: SYE (http://www.oconeeoffroad.com/servlet/the-1950/Jeep-Slip-Yoke-Eliminator/Detail)... apparently they have been doing free shipping for a while... so it is $180 shipped to you... and you just pick up another front DS from the JY for an XJ... so that is my plan... don't even have to touch the bolts/studs (cause just my luck they will all snap off)...