While Brian from JCROffroad works on the rollcage for SSDutch, I’ve been doing a “dualing transfer case rebuild” project along with local Jeeper Mike Oakes.  Mike’s tcase started sounding kinda bad during the last Silver Lake trip, and I had 2 spares that I wanted to rebuild into one fresh unit.  The transfer case on SSDutch seems to function OK, but leaks badly (more than “normal"), and has a stripped bolt where the driveshaft attaches.  I figured it would be easier to rebuild one of my spares and just swap it onto the Jeep when done.

We also used some of my spare parts to convert Mike’s single-stick to a twin stick.

We’ve been using master rebuild kits from Novak, Rick Stiver’s excellent Dana 18 Rebuild Guide, and are right at the point of installing the new intermediate shafts.  So far it seems to be going well - it really helps to do two at once like this, both for parts comparison and figuring out the process.

After some more work and a coat of paint: