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Originally posted by yoda
Monty, Based on the year of your Jeep it should have a Dana 18 transfer case in it, but becuase you say that it only has one shift lever, I'l assume it is a Dana 20, since the rest of the drivetrain is non-Jeep. Is the rear output of the transfer case centered or is it ofset to the passenger side? The rear axle will also either be centered or offset to the passsenger side. This will tell me which case it is. You say it should be almost new, I'm guessing you mean recently rebuilt since niether of the two t-cases I mentioned above have been manufactured in more than 20 years. Does the t-case work correctly in 2wd, does it whine or make any clunking noises? I've rebuilt quite a few of both cases, and can honestly say that you are going to have to pull the t-case and tear it apart to figure this out, as there is definately something wrong with it. If its a centered rear output, then its a Dana 20, if its offset to the passenger side then its a Dana 18. Either way, it needs to come out and be opened up to figure this one out. My guess is someone rebuilt it and didn't reassemble it correctly.

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