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242 replacement problem

Old 03-10-2019, 01:50 PM
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Default 242 replacement problem




Alright, I just recently bought a 96 Grand Cherokee 4x4 that came with a busted NP242 transfer case in it. I found replacement from a guy, he claimed it was from a 2001 or 2002. I thought Iíd be able to change the sensors out from my old one and bolt it in but I have run into a problem with both sensors. My case has a (I believe it is) Speedo gear/sensor mounted in the rear portion of the case..well the one I got for replacement has a spot for that sensor..but itís blocked off, as in no hole to insert the gear into..thatís my main issue.. the other senor next to the vent tube is just a bit too long on my old one. Iím assuming I have to take them apart and change the output shaft portion of the case from my old one to the new one to make the speedo gear work? Iím new to Jeeps so Iím just trying to get some guidance before I put it in and have to pull it back out, thanks for any help! Also if I do have to change the cases out will the newer one have the gear inside to drive the speedo gear?
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Old 03-10-2019, 05:15 PM
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All you need to do is change the tail housing on the case. Be sure to take your speedo drive gear and change that over too
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Old 03-10-2019, 05:51 PM
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Originally Posted by 4.3L XJ View Post
All you need to do is change the tail housing on the case. Be sure to take your speedo drive gear and change that over too
Thanks! I just didnít know if Iíd have to change the whole mainshaft not knowing if the gear that drives the speedo could be changed by itself or not, appreciate the info 👍
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Old 03-10-2019, 05:54 PM
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The only thing that would affect that is if the other tail shaft does not have a slot in it for a snap ring to hold the speedo gear in place
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Old 03-10-2019, 08:01 PM
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Originally Posted by 4.3L XJ View Post
The only thing that would affect that is if the other tail shaft does not have a slot in it for a snap ring to hold the speedo gear in place
not sure about that, probably wonít have it apart until tomorrow or Tuesday. Guess Iíll see.
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Old 03-10-2019, 08:05 PM
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I'd be tempted to try knocking the plug out. If it's anything like a freeze plug you tap one edge and it rotates then you pull it out with pliers
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Old 03-10-2019, 09:11 PM
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Originally Posted by SatiricalHen View Post
I'd be tempted to try knocking the plug out. If it's anything like a freeze plug you tap one edge and it rotates then you pull it out with pliers
Iíll give that a try, but I did go ahead and remove the boot on the tail shaft and the metal dust shield and tail shaft seal and there is only one snap ring down in there around the tail shaft up against the bearing..my old case has two snap rings..the same one and one more about an inch up from the bearing.
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Old 03-10-2019, 09:57 PM
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Well I got the rear portion of the case off and it has no gear for the speedo.. so now my question is does anyone know if I buy a new main shaft for a 96 242 will if fit in this newer 242 with using all the newer parts of this shaft? Are they interchangeable? I hope so or I just wasted money on this case..
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Old 03-11-2019, 10:07 AM
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As far as I know, they are the same. Why not use your old one?
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Old 03-11-2019, 01:05 PM
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Originally Posted by 4.3L XJ View Post
As far as I know, they are the same. Why not use your old one?
Iím going to take my old case apart tonight and see about using it, I was told when it broke they were doing about 60 mph, so Iíll clean it up once itís out and make sure it doesnít look damaged and go from there. Thanks for the responses! Iíll post back when I find out something.
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Old 03-11-2019, 02:50 PM
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Also one more thing I just ran into today. There are three different lengths on the input gear. I will be changing one out as soon as I post this. Make sure whichever input you use, it is the same length as the one coming out
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Old 03-11-2019, 04:51 PM
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Originally Posted by 4.3L XJ View Post
Also one more thing I just ran into today. There are three different lengths on the input gear. I will be changing one out as soon as I post this. Make sure whichever input you use, it is the same length as the one coming out
well I have both tail shafts out and they look identical without taking them any further apart..and looking at the one out of the newer case, it has some rust on it, I suppose from sitting so Iím thinking I could just put the old assembled tail shaft right into the newer case and call it done..I was thinking of swapping the newer parts to the older tail shaft but I donít like the rust all over them.. so is there anything in particular I should do before swapping these things or just look them over really good to make sure all is the same and nothing is damaged on the old one and then just swap em?
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Old 03-11-2019, 04:56 PM
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the one on the right is the one out of the newer case and as you can see it has plenty of rust up and down it.
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Old 03-11-2019, 07:15 PM
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Look them over and go for it
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Old 03-11-2019, 09:31 PM
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Originally Posted by 4.3L XJ View Post
Look them over and go for it
Went together nicely!
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