2004 TJ Rear Driveshaft Shaft Help

[Slaughterrt]

Hey all. Could use a little help here. This morning, on the way to work, the rear propeller shaft decided it no longer wanted to associated with the rear differential and the transfer case. I heard a loud bang and lost my gears. I was able to coast to the shoulder and investigate. Turns out that the “rear propeller shaft” was completely missing. My apologies if this is not the correct term. It is the shaft between the transfer case and rear differential (as I mentioned above). So, I put the beast into 4WD and was able to use it as a front wheel drive vehicle for the final trek of my journey to work…successfully.

So I have the Jeep parked in a safe location where I can leave overnight for however long I need to. Also have other vehicle options for driving. Time is not necessarily of the essence, but obviously want to get it back on the road.

Question 1: is it safe to drive the jeep in 4WD back and forth for a few days, or would this cause too much wear and tear, and possibly damage other components?

Question 2: is this a diy job or something that would have to be done professionally? It appears to be a bolt-on component. The differential side looks easy enough to replace at the u-joint, but I’m not as confident on the transfer case side. Can someone point me in the right direction as far as parts needed and a run down of the process of replacing it?

Question 3: it looks like the shaft completely snapped at the plate (removable plate?) on the transfer case. Is this going to be an issue or is this part of what would come with a new shaft?

Thanks everybody. I’m just trying to brainstorm and plan this out. I’ve replaced/worked on many parts of the Jeep (and vehicles in general), but not this. Thanks for any advice.

 

[LakeBeard]

That's called a rear drive shaft. Its an easy replacement, bolt on and can be done in a beer or two. I would be more concerns w/ why it happened. Seems like it had to bind pretty good to snap like that.

 

[mrblaine]

That's called a rear drive shaft. Its an easy replacement, bolt on and can be done in a beer or two. I would be more concerns w/ why it happened. Seems like it had to bind pretty good to snap like that.

Both of you are right. We call it a drive shaft, the factory calls it a propeller shaft. His is not an easy replacement since he needs a new output shaft in the t-case since the part with the splines seems to have left the chat along with the driveshaft. And he'll need to pull that damper off and reinstall it on the new output shaft.

 

[Slaughterrt]

That's called a rear drive shaft. Its an easy replacement, bolt on and can be done in a beer or two. I would be more concerns w/ why it happened. Seems like it had to bind pretty good to snap like that.

Not sure if there was a “straw that broke the camels back” instance…but I had noticed some extra road vibration the past week or two. My initial thought was a bad 02 sensor, because the vibration corresponded with me getting two CEL indications. One for O2 sensor and one for cylinder misfire. Ironically I replaced the O2 sensor last night after work.

I guess the CEL codes will go away at least…

 

[Slaughterrt]

Both of you are right. We call it a drive shaft, the factory calls it a propeller shaft. His is not an easy replacement since he needs a new output shaft in the t-case since the part with the splines seems to have left the chat along with the driveshaft. And he'll need to pull that damper off and reinstall it on the new output shaft.

After doing some research and talking to my brother-in-law (former professional mechanic), the plan is to replace the drive shaft and the rear diff yoke. From the few videos that I have watched, it appeared that the output shaft should just slide out of the transfer case (albeit with force im sure). I could certainly be wrong with that understanding.

I recognize that it’s not as cut and dry as unbolting the shaft from a couple of ujoints. But from some of the replacement product pictures that I have seen, the drive shaft kit appears to include the shaft part that slides into the transfer case. It is sorta hard to tell exactly though. And also, having not removed the drive shaft, and not having the old one, it’s hard to compare to the potential replacement ones.

 

[Slaughterrt]

Both of you are right. We call it a drive shaft, the factory calls it a propeller shaft. His is not an easy replacement since he needs a new output shaft in the t-case since the part with the splines seems to have left the chat along with the driveshaft. And he'll need to pull that damper off and reinstall it on the new output shaft.

Actually scratch that. You are correct about the output shaft on the transfer case being broken off.

 

[JKP]

U joint failure.

Now is the time to check the front driveshaft U joints because if the double cardan joint at the tcase end fails it will destroy your tcase as it vacates the Jeep.

 

[Slaughterrt]

U joint failure.

Now is the time to check the front driveshaft U joints because if the double cardan joint at the tcase end fails it will destroy your tcase as it vacates the Jeep.

This is good to know. Thanks

 

[Slaughterrt]

So assuming that I can buy replacement parts for the output shaft on the transfer case, what would be the process of installing the new output shaft? I think replacing the driveshaft is fairly bolt-on, and same with the new yoke for the rear diff. Just getting stuck on the transfer case part? Is this something that a guy can successfully do in his driveway? Opening up the transfer case isn’t my concern…it’s successfully putting it all back together (correctly).

 

[OldBuzzard]

Depends on the guy wrenching, I guess. You have to remove the tailhousing, and the transfer case rear cover, and remove half of the guts. That tailshaft is long, goes almost to the front of the TC. Look up some of the SYE installation threads, they'll show you what is involved.

 

[Slaughterrt]

Depends on the guy wrenching, I guess. You have to remove the tailhousing, and the transfer case rear cover, and remove half of the guts. That tailshaft is long, goes almost to the front of the TC. Look up some of the SYE installation threads, they'll show you what is involved.

Thanks. Will check out those threads.

 

[Rickyd]

At the very least you need the transfercase output shaft,bolts and straps for the rear yoke and a driveshaft.hopefully the rear yoke isn't damaged. I would check the yoke for forward/backward,side/side play.

maybe replace that leaking seal and crush sleeve while you're at it.

Is it lifted? Maybe an sye kit and new double cardan rear shaft are in order?

 

[AndyG]

Man- that’s a headache.

Haven’t seen that much.

 

[Slaughterrt]

At the very least you need the transfercase output shaft,bolts and straps for the rear yoke and a driveshaft.hopefully the rear yoke isn't damaged. I would check the yoke for forward/backward,side/side play.

maybe replace that leaking seal and crush sleeve while you're at it.

Is it lifted? Maybe an sye kit and new double cardan rear shaft are in order?

Yea…looks like a new output shaft for the TC, a new rear driveshaft, and prob would replace the rear yoke while I am at it…and as far as the leaking seal…might as well since it will be all accessible anyway. My bro-in-law replaced the seal once already, several year ago, and it immediately started dripping (very slow leak). Said screw it and have just been topping it off every 6 months or so.

As far as lift goes, there no list. Everything is stock except the 31” ATs. Would it make sense to do a SYE on a stock TJ (with no intention of lifting). I’m looking for the most reasonable decision cost-wise. The Jeep has over 200k on it, and although it’s been reliable for years, I’m hesitant put a ton of “extra” money into it. That being said, I do want it to be reliable since it’s my DD.

 

[mrblaine]

Yea…looks like a new output shaft for the TC, a new rear driveshaft, and prob would replace the rear yoke while I am at it…and as far as the leaking seal…might as well since it will be all accessible anyway. My bro-in-law replaced the seal once already, several year ago, and it immediately started dripping (very slow leak). Said screw it and have just been topping it off every 6 months or so.

As far as lift goes, there no list. Everything is stock except the 31” ATs. Would it make sense to do a SYE on a stock TJ (with no intention of lifting). I’m looking for the most reasonable decision cost-wise. The Jeep has over 200k on it, and although it’s been reliable for years, I’m hesitant put a ton of “extra” money into it. That being said, I do want it to be reliable since it’s my DD.

With those miles, I'd snag a lower mileage 231 and swap that in with a new driveshaft. Then test it on jackstands to see if there is any wobble at the pinion yoke. Faster, easier, and better than adding parts to that 231. That said, if you want to throw parts at it, I can round up a 231 shaft for the cost of shipping.

 

[Rickyd]

Would it make sense to do a SYE on a stock TJ (with no intention of lifting).

no, it wouldn't really justify the extra cost in that case