Hack N Tap for the 242....
 

Who all sells a Hack N Tap kit for the 242 T Case???

also I hear of some using a front drive shaft off of an auto XJ in the rear after intalling an SYE. Will I be able to do this after a Hack n Tap install on my 1990 AUTO XJ?????

Yes you can use a front drive shaft in the rear after a Hack-n-Tap.

I know RE has one and I think Tom Woods drive shafts sells one....

Rubicon Express sells the Hack n Tap.

Yes, you will be able to use a front DS out back with this set up.

Make sure you get the correct Hack n Tap from RE. They have one version for the pre 96 crowd, and one for the post 96 crowd. The reason for the two is for a different set up on the older tcases vs. the new. On the old ones, the tailcone contains some of the ATF that the tcase uses to help keep things lubricated. On the newer tcases, the tailcone was re designed and it's dry.

IMO, it's easier to do a H&T on a newer 242 because of the fact that the older ones like to leak, due to the tailcone set up. On the other hand, for an affordable SYE for the 242, the H&T is about your only option.

I put a RE HnT on my '90 a few years back and never have had a drop of anything leak out. Was much easier than I anticipated but was kinda scary doing it but it worked out just fine.

what is a hack n tap?

It is a kit to install a SYE on a 242 transfercase. They have several differences from the 231 case.

You actually cut or "hack" the output shaft on the t-case and tap the end of it afterwards. AKA hack-n-tap, HTH!!

the PO who installed my hack n tap fudged up the seal and housing so it leaks like a sivv...

thats why i just got a 231 :)

Can you do anything to seal the 242 once you have it on the bench?

Yep, I can... looks like they took a BFH/BFS to a precision sealing surface :brickwall:

Take the short collar off the tranny and smooth the surfaces of both sides. Call the maker of the HnT and ask them for a new seal. After you have both sides smooth then put a bead of RTV around the sealing surface after installing the new seal. Re-assemble everything and re-fill with Dextron III and tilt it so the HnT is at a low point and check for leaks. If you got the two surfaces flat then the RTV will have filled the imperfections and you can re-install your 242.

well that sounds like a good ideer blue... its almost like the tail housing on the 242 is damaged very badly i dont know if sanding it down will fix it tho.,

It is worth a try. Since the parts are aluminum use a block when sanding to get a level surface to seal against.

I will definately look into it :)

Will the auto front drive shaft work on a 5-speed/231 with a SYE?