Rebuilding NP231- suggestions?

[Sam Stein]

I am planning to order a SYE kit for my 91 YJ 4.0/AX15. It has 130-140K miles on it and I can't see pulling the transfer case all apart without rebuilding it. I tried a few searches and didn't find any write-ups on this, although I did find the NP231 manual at pirate4x4. I figure that if I mess the whole thing up, I'll only be out @ $75 for the overhaul kit.

One question: It seems that the overhaul kits come with a replacement chain. I know that with motorcycles and bicycles, it doesn't pay to mix new chains with old, worn sprockets. Does that not apply here?

[Neomonk21]

BTT, I am interested in this as well....

[LeadFoot]

As long as your gears are fine and not severly rounded off, you'll be fine with just a new chain. I've rebuilt two of them already and both are going good. Check the bearings too, change them if they need to since your already that far. Replace the seals also if they are cracked or starting to get stiff.

http://community.webshots.com/photo/118893173/118894439hntCMZ

[steeve555]

My rebuild kit came with bearings and seals. I had to get chain seperate. I used factory service manual for rebuild. Chain sprockets were fine.