Cracked transfer case output

[TwistedCU]

Crawled under the Jeep today just to do an occasional once-over. Glad I did. Well I have no idea how long it's been like this but the tailcone for my NP231 transfer case has a bunch of stress cracks in it. One is longer than the rest (circled in one of the pics) but the rest are about the same and all the way around.

Here's my question:
Should I fix this thing before I re-do the suspension (about a month and a half away)? Or do you guys think it will hold up until I throw the new suspension on there. I am planning on re-doing everything. New brake lines, long arms, F&R springs, SYE/New driveshaft, bla bla bla.

If I fix it now, I'll have to use stock parts, which I am going to replace soon anyway. If I were to do the SYE and DS now, the DS will be too short when I re-do the suspension.

I haven't done any hard wheeling in several months. I've been too busy. I have done alot of hauling but I doubt that did it. Not sure what caused it or how long it's been like this but I don't want to cause an accident the highway going to work.

I should add that it is not leaking anywhere.

Help a brotha out with some advice. Here's pics:

 

[Bounty__Hunter]

I'll check all of mine, but those look pretty normal as long as they're not clean through and leaking.

I'd leave it until the SYE.

You could do the SYE now if you have the driveshaft built 1/4" or 1/2" long. Your driveshaft length won't change much unless it's a drastic change in lift height.

 

[TwistedCU]

I'll check all of mine, but those look pretty normal as long as they're not clean through and leaking.

I'd leave it until the SYE.

You could do the SYE now if you have the driveshaft built 1/4" or 1/2" long. Your driveshaft length won't change much unless it's a drastic change in lift height.

I'm only going 2-2 1/2" higher

They're not leaking... it didn't look like that before, but it has been a long time since I really looked at it.

 

[Bounty__Hunter]

I wouldn't worry about it.

You can do the SYE and shaft before the lift, the driveshaft length won't change enough to worry about since it's more horizontal.

 

[TwistedCU]

Have you (Bounty) had a look at yours?

I posted a similar thread on NAXJA, and all I got was it's probably casting marks or welding slag. It doesn't look like either to me. Just wondering if yours (or anyone else's) looks similar...

 

[Saurian]

I'll have to take a look at mine, same year and all, and from what I can gather, pretty comparitive use. Haven't been under it in forever, been so busy with my brother's grand waggy...

 

[Bounty__Hunter]

Haven't looked yet, but going by memory it looks like tailcones I've seen before. I've got about 1/2 dozen of those in the garage from SYE installs, let me take a look.

 

[Bounty__Hunter]

Have you (Bounty) had a look at yours?

I looked at all 6 I have in the garage, all are that way. None of the imperfections are cracks that continue all the way through to the inside of the tailshaft housing.

I've also got 5 YJ tailshaft housings, so I'm a little 231 parts heavy if anybody needs anything.

I've also got the following speedo gears:
Short
37t

Long
29t
34t
36t

$10 each. bountyhunter@sija.org .

 

[TwistedCU]

I looked at all 6 I have in the garage, all are that way. None of the imperfections are cracks that continue all the way through to the inside of the tailshaft housing.

I've also got 5 YJ tailshaft housings, so I'm a little 231 parts heavy if anybody needs anything.

I've also got the following speedo gears:
Short
37t

Long
29t
34t
36t

$10 each. bountyhunter@sija.org .

That reminds me Bounty, didn't you have a formula or a link to a calculator for knowing what speedo gear is needed? I need a new one for my XJ:
3.55 gears, 32" tires. Stock tire size was 225x75r15

Oh, yeah and thanks for checking into the TC output.

 

[Bounty__Hunter]

Here's a good one: www.jeeptech.com/javaAps/Speedo.html

Here's more good info, and part numbers: http://go.jeep-xj.info/HowtoSpeedoGears.htm

Check with www.tacomaspeedometer.com as they carry most all speedo gears. The stealerships don't carry speedo gears for older models. Tacoma Speedometer was fast and great to deal with.

 

[TwistedCU]

Ah, that's it, thanks again