Hatsuwr

Hey everyone, I took out my transfer case to fix a leak and clean the collection magnet. While I have it disassembled, do you all recommend doing anything else with it?

Its a NV242 (or NP242... not quite sure the difference) from a '96 ZJ. I have no knowledge of its service history for the first 20 years of its life.

Besides some strings of excess RTV floating around inside, the case seems to be in good enough condition. I don't really know what to look for though.

Thanks, and happy Thanksgiving!

dave1123

Okay NP vs NV. New Process Gear changed it's company name to New Venture Gear when the employees bought it from Chrysler. The product is identical. A bit of history, the company now belongs to Magna Powertrain. The company was based right here in Syracuse and I knew many people who worked there.

I would check the nylon "slippers" on the shift forks for cracks or being missing, and the drive chain for being stretched. If your leak was a shaft seal, check that bearing for wear that may have caused the leak. Remember that a leak from the input housing may be from the transmission. You may want to replace that seal as well.

Happy Thanksgiving and keep on jeepin' on!

Hatsuwr

Well, I just about finished up. The forks and slippers look good and are all there, chain is fairly taut, seals are intact, and bearings don't have excessive play. I put in a Fel-Pro gasket. Hopefully it all holds!

One small thing holding me up. When de-rusting parts, I lost track of where these two little brackets go. These are my best guesses. Anyone able to confirm?

Hatsuwr

Got it. #1 is correct. #2 should be the bolt just up and right of where it is marked in the picture. Not that is matters much, but #1 seems to be installed with the hook to the right and #2 extends toward the rear of the vehicle.

dave1123

Yes, #2 is for keeping that fat harness away from the muffler and driveshaft.