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I've got a '95 ZJ limited with a 249 TC (Quadra-Trac) fulltime 4wd. How often will the viscous coupling in the transfer case wear out and how expensive is it to replace. If it is bad, would a Transfer case replacement be a good idea and which should I get. I heard that the '95 249 doesn't lock the f/r axles in 4Lo but the '96 does.
 

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Heard a lot of horror stories in various forums. Yet, a long-time Jeep dealer mech I trust told me there were some bad welds on some of the early '95s, which let the Dexron in the T-case contaminate the silicone inside the clutch, and they showed up around 30,000 or less. I've got about 108K now and no problems. Ben
 

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Got 166K on mine. No problems at all.
But I do change the fluids every 20K.

My father had 176K on his last ZJ...no problems there either.

<font size=-1>[ This Message was edited by: chrism on 2002-03-28 09:07 ]</font>
 

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As Ben was saying, the main problem experienced with a 249 is viscous diff weld, allowing fluid contamination. This would be observed as crow hop during a low speed tight turn (like having 4wd lock).
The other possible problem is when you up the output of your engine, the chain can wear into the sprocket. But I have 100k on mine, and have not heard of too many field failures of chains (unless someone runs it with no fliud, dearler service.....)
 
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