The '95 Sport (auto, 178k miles, 4.0, 242J t case)...had the grinding in the transfer case (in everything but 4 lo..would 'grind' and not move). I did a bunch of stuff with it yesterday and as part of that, 'drained' the T-case. About couple of tablespoons came out...black like oil (looked like no metal particles, but hard to tell from the thickness/blackness). Per the manual..should have a qt of trans fluid in it.

I refilled with fluid, and won't get a chance to try it for a while (seats out to get cleaned...need to rip out the carpet and fix the rust-through holes among other issues)...so, as I wait for things to come in and be done, I'd like to have the parts in hand (if I need a new T-Case or a rebuild) so I can work on them while waiting for paint to dry, etc.

When it's been run without fluid (not my fault...I just got it and couldn't check before driving home), is the innards of the T case toast?

Worth rebuilding myself (NP 242 T-case)?...I can handle brake rebuilds, pushing in wheel bearings, etc, but couldn't rebuild an auto trans (to give my level of incompetancy!). Cheap kits to do it? Need a new chain?

And, finally...the recommendation made frequently is for the 231 swap. I'm in PA, so the 4 Hi F/T would be nice for the occasionally snowy roads, but not mandatory. For a 231 swap, what ADDITIONAL parts would I need (assuming the same year/spline count, etc.)? Are the speedo sensors the same, etc.? The shifter bezel would have to be changed, correct?

Thanks!

AFARR

 

could be, don't really know without breaking it open and looking. I would replace the fluid (2.2 pints of dexron II/atf+) and see how it performs.

If you do want to rebuild it, follow this guide
http://www.mallcrawlin.com/forum/showthread.php?t=8549

As for a 231 conversion, not really sure - here is a guide for the reverse swap (231->242)
http://www.weatherlover1.com/jeep/242.htm

 

Did the fluid replace.

What would I look for if I broke it open?

Thanks!

 

worn chain, worn syncro teeth, worn bearings.....

 

if you dont know what your doing, dont open it. it gets a little confusing.

 

But that's how I learn..


I figured that if I screw something up (the link above has some nice pics...different output type, but basically the same unit), I'm not out anything....

However, I'm leaning towards getting a direct replacement (242J), swapping it in (as a used unit), then maybe playing with the old unit to learn more about it...and possibly rebuilding it.

AFARR

 

is it still making the grinding noises and not moving in 4lo?

 

Need to fix the thermostat leak (my fault...probably didn't seat the thermo right), and bolt the seats in to test it...

It was ONLY moving in 4lo (grinding in 2Hi, 4hi).

Thanks!

AFARR

 

ok report back

 

Got the cooling and no-start issues mostly sorted out. Was able to start it today, and it still grinds in everything but 4Lo despite being filled with fluid. I'll still pull the adjuster off and free it up..but I think it's probably in the case rather than in the adjustment.

Guess I'll be in the market for a T-Case (I think I'll look for a cheap 242 case for now...23 Spline, 95 & down (output shaft is different on the 96+ models).

Or...how much should it cost for a rebuild if I carry it in somewhere?

Thanks!!

AFARR