NP231

In my opinion this transfer case has three flaws. It has an aluminum case, it is chain driven and it comes with a slip yoke output. As far as I know, the only thing you can do anything about is the slip yoke. Here are some of the problems with the slip yoke. If you ever lose the rear drive shaft you will also lose most of the fluid in the t-case and with this setup the t-case output yoke and the rear diff yoke must be parallel, this will give you some extreme angles with higher lifts. To remedy this problem most lifts will come with some kind of t-case lowering kit, which just takes away from your valuable ground clearance. There are a bunch of SYE kits on the market, some are good and others are poor. I think that the saying "you get what you pay for" applies here. Several of the kits (the cheaper ones) require you to cut your existing output shaft, drill and tap it. Although this can be done I think there is too much room for error. Other kits will provide a new output shaft that will replace the old one. Two kits that come to mind are the JB and the MIT kits. I believe that the JB kit comes with a larger and stronger shaft. I am running the MIT kit, I was thinking of going with the JB but I came across a deal that I couldn't pass up. The internals of this case are fairly straight forward and the kit is a breeze to install. The only real hard part is removing it from the tranny, some of the bolts are kinda hard to get to. Once you have the case open it is just a matter of pulling the gears off of the old shaft and placing them on the new one. The entire gear assembly should come off in one piece. There will be two c-clips holding all of this together, one holds the gear assembly onto the main shaft and the other one which is located on the outside of the speedometer housing and helps hold the shaft in place. The c-clip located outside of the speedo housing will not be reused. The SYE kit is only half of the drive line resolution, a good drive shaft with a CV joint is the other half. Without the CV you still have a problem with drive shaft angle.

Notice the oil stain on the underside of the body, the rear seal of the stock slip yoke output didn't hold up very well even after I replaced it.