So I finally figured out that the loud whine I get on acceleration is coming from the transfer case. I switched it to part time and the noise goes away? as far as I can tell at least...? Any ideas or experience on this? Dad is suggesting just buying a new one and swapping cause it also gets stuck in 4x4..Whata you guys think? I'll try to make a video of it and load it to youtube and post here...any help will be taken, Thanks!!


OH snap all most forgot, Pops changed the fluid when I had it at his shop for something else, said it was black enough for him and the tech to say, "damn"..but even with new fluid noise is just as bad


2001 XJ Sport 4.0L NP242TC, stock

 

Black fluid is burnt. Once it is burnt it looses its lubrication properties. Then bearings go bad.
Does the front output shaft/yoke have any play or slop?

The 242 is known to get 'spline lock' due to torque load after running in 4WD. Usually will have to reverse to get it unlocked.
I have had two 242's that act this way. One was fully remanufactured, including shift fork.

Here is good reading to familiarize yourself;
http://www.rsgear.com/articles/1994_02.pdf
http://www.novak-adapt.com/knowledge/np242.htm

 

The chain that drives the front yoke is known to get slack and rub on shell of TC. When shifting into 4WD the slack may be taken up.
However, this does not really fit the sound you describe. The description sounds like a bearing.

 

Yeah im afraid im going to need to rebuild...trying to find one cheap around where I live..found a couple on ebay inside the $200 range before shipping..how much do you think I SHOULD pay for a junk yard or part out?




Here are a couple videos I made today! In the second one you can see my new headliner my brother and I put in..


https://www.youtube.com/watch?v=laYH...ature=youtu.be
https://www.youtube.com/watch?v=Igpz...ature=youtu.be

 

$100 low - $200 high, for a used case. If you could find one from another jeeper, often the condition of it would be better known.
The Grand Cherokee WJ uses the 242 also.

 

or this


http://www.novak-adapt.com/catalog/t..._242_parts.htm

 

I am 100% willing to rebuild it myself I just do not have the correct tools for removal. And my pops cant let me use his shop for liability reasons(works at big name dealership).. so it looks as though I will have to replace cause that's all he said he was going to help me with lol, not rebuild... so if im looking for a transfer case in a junk yard or online, are they all the same if it says model "242 J", like off a different model vehicle, or no?

 

For removing the transfer case you will need only three tools, 5/16" socket and wrench for removing driveshafts. 9/16" to unbolt the case. Then it slides off transmission output shaft.
Weighs almost 80 pounds. When I do it solo I put a piece of plywood on my chest to lower it onto.
Top bolt that mates the case to transmission can be difficult to reach. Short 9/16" wrench works best (some tie a rope onto wrench to pull).

As for a matching case, I suggest researching because there are different lengths of the input splines depending on the tranny it was mated to.
A guaranteed fit would be getting one mated to the same tranny as yours.
Otherwise the 242 will have to be opened to swap the input.

Removal is not difficult but rebuilding is more involved.
I also suggest a search for write-ups on switching out the case and for rebuilding it. Familiarize yourself.
https://www.google.com/?gws_rd=ssl#q...r+case+removal

 

man, any videos for removal on Cherokee?

 

The 242 and 231 remove and install using the same procedure.

YouTube vids; https://www.youtube.com/results?sear...moval+cherokee

Write-up http://mallcrawlin.com/forum/showthr...n-of-the-NV242

http://jeep-xj.info/HowtoChainChange.htm

 

What the heck is this? ?...looks like there is suppose to be a lock ring in front of the seal and a snap ring in the grove in front of bearing..where could it have gone? And is that shaft play normal? ? I looked through this link you gave me and saw where the rings were suppose to be, so far the only ring I've come across is one lock ring between bearing and seal http://mallcrawlin.com/forum/showthr...n-of-the-NV242

 

231 is stronger, less issue prone case. Is there a reason you wanna keep a 242?

 

Funny you say that..



After i took out the speedo gear i saw this behind bearing in rear retainer..this is why my bear/shaft dropped..piece broke clean off right behind bearing..

 

Greetings
Yesterday i bought a replacement transfer case (np 242) which was taken off a 2001 xj and im installing it on my 1996 zj. I attempted to mount to transmission and it wont slide all the way on..theres no apparent difference with new imput shaft, but the new tcase appears to have longer studs that are too much for my zj...any idea how i change
these out w the old ones?



C

 

There are different length input shafts.

Perhaps someone else will chime in with more knowledge about that than I.