Just rebuilt my np242 and the seal I put in was bad, started leaking fluid like crazy. I drove the case dry for 80 miles or so up-hill in 2wd, when I was coming home downhill I experienced bucking and had my rig towed home. Shop found metal in the transfer case fluid and so I brought it home and took it apart. Found that some of the shift fork pads had melted and disintegrated, I'm guessing the metal came off the shift fork which seemed like it had worn down quite a bit. My question is, what might have caused this? Could it just be a result of the the case being driven without fluid? Should I just replace the pads and call it good or replace the shift forks as well? What about the shift collar? Thanks for any advice!


What my seal looked like

Magnet

Pads on lower shift fork beginning to melt


Upper shift fork with wear