Hey folks.

I am getting close to the point of needing to get inside my transfer case.  Something new to me.  There is a lot of slop on the outputs... especially out to my front driveshaft.  Its making quite a bit of vibration through the stick.  After our last mud bog event its gotten worse. I've already put in all new u-joints.  Another issue that popped up since then is it seems like one tire is staying locked in.  Hubs unlocked, it pulls very very hard to that side... unlike ever before.  I suppose that may be hub related? I do have auto lockers front/rear. Theres a pretty bad shimmy on pavement while in 4-low locked or unlocked. Also, I did rebuild the front axle with all seals/bearings about 150 miles ago.

Just looking for any pointers or BOTF's.  I am sure this is something I can handle myself... but may be worth having prof done?

My other consideration is with having this turbo and added power on the 16v (http://www.driftwoodchimes.com/zuki1018), I wouldn't mind stepping up in tire size.  Currently running 31's with YJ's and missing links on the front. Most of our driving is trail ride or mud... steep sand hills here and there and very little pavement other than "to" the trail a few miles away.  I think the trucks looks a lot better on 33's.  I do have a set of 20x12.50's with 35's collecting dust!!  Anyway, I want to add this to gear considerations when i move forward on the transfer case.

Comments or pointers much appreciated.

Don't have any personal experience with Sammy Tcases, but rebuilding a Trackick case isn't all that difficult if you have the tools, pullers, press , etc.
Sounds like one of your hubs has taken a crap too. It's that mud I tell ya! 

Don't have any personal experience with Sammy Tcases, but rebuilding a Trackick case isn't all that difficult if you have the tools, pullers, press , etc.
Sounds like one of your hubs has taken a crap too. It's that mud I tell ya! 

Lets just say mud did take its course!  I need to start changing all gear fluids after every mud puddle lol.  Guess its time to add a press to my tool lineup!

T case rebuild is not to scary. By the description of your Zuke , you auta be able to handle it. Regaer it while you have it apart:
6.51 for 33s.
Check your hubs first , then check your locker, for your front end problem.
 As to turbo . Good luck with that. .....Boxcar...

T case rebuild is not to scary. By the description of your Zuke , you auta be able to handle it. Regaer it while you have it apart:
6.51 for 33s.
Check your hubs first , then check your locker, for your front end problem.
 As to turbo . Good luck with that. .....Boxcar...

Ugh, man they are expensive!!! ...then beefing up the t case mounts... then adding MORE pressure to the 3rd's bearings...  where does it ever stop haha.

It was my outter bearings.

Turbo:  did great.  we drove for 3 hours yesterday mid-day Florida temps (still fairly cool) and didn't have any temp issues.

T case rebuild is not to scary. By the description of your Zuke , you auta be able to handle it. Regaer it while you have it apart:
6.51 for 33s.
Check your hubs first , then check your locker, for your front end problem.
 As to turbo . Good luck with that. .....Boxcar...

...looks like my t case has been worked on before.  How do you tell what ratio the gears are... divide similar to the 3rds?

Eather jack up the rear wheels , or drop the rear drive line.
 With the tranny in neutral , and the transfercase in low , turn the input shaft of the T case .Watch the output . 6 turns in front to 1 turn in rear is 6 to 1......Get it ?... Boxcar...