Now it's time for the final touches before I declare it's done and ready to install 😁


I got the drail plugs and sight glass installed.


A closer view. I wanted a sight glass with a larger window I found this was limited. There were a couple online that were both larger and annodized red just like the drain plugs, but meant I would have to drill and tap the hole it larger. I chose to keep it stock incase if it were break, I could replace it with another drain plug. Maybe one day I will change it.


The drain plugs are annodized aluminum with a built in magnet. The aluminum plug is nice because it is easier to replace the plug than a transfer case housing.


I also snapped a couple photos of the inside cleareances before I siliconed it together.


Another view.


This is the stock WJ shift sensor. Because I am using the factort XJ one, I am installing it into the AMG housing. This is another reason why I swapped out the shift sector for the J case one. I mean they were exactly the same apart from the back end, but its just unnecessary weight. Easier transfer case shifts and better gas milages if you wanna call it that 😆


Since I am doing the delete, I used the old detent to plug this hole. As minor as it may be, this is two fold: i dont have to buy a new bolt, and i have a spare detent.


I got the speed sensor and the XJ shift sensor into the AMG housing.

 

You've inspired me, thanks again for posting all this. I've run across another NP242HD in the junkyard. I plan to go pick it up tomorrow with a buddy. Its in a WJ V8, the part number matches other threads I've found online, it's got the aluminum tailcone and the cooler cast in bumps, so I'm confident I've found the right one.

Question for you - anything else with respect to the transfer case swap you wish you had from a WJ 242 donor?

And did the front output shaft have any significant front to rear play in yours? The front driveshaft and output yoke are missing from this junkyard example, so that may impact it.

I've got a spare regular 242J sitting around, so I plan to copy a lot of this thread and bash them together into one super case.

 

I admire the OPs thread, and his work, its reeks of excellence, let me make that clear

someone please educate me though, why go to all this trouble & expense ?

I presume this version of the NP242 is way stronger and can take more torque, so would be good for a big torque engine build ?

However the stock NP242 is a strong unit, that can be easily and cheaply rebuilt, and is by no means a weakling

I have not seen a TX case upgrade mentioned as a must do for Strokers or even LS swaps

I have lower mileage spare I bought for $100 if my 240k mile one decides it needs a rebuild

 

1. Parts from the 242 donor? Probably not. And what I mean, I'd I didn't pull it myself so I'm not exactly sure. The one thing I still need to source is a new front driveahaft (for the rear). Depending on the configuration of the WJ, i may have taken that. But really I want another XJ one so I can use either one in either spot, and be able to carry a third. All three can be used in the same spot regardless.

2. My HD case had almost no play in it. I wish I had more money to rebuild this more properly, but I guess you could call this a budget build. I inspected all of the bearings, seals, and snaprings and didn'treplace them. The HD case I got was rebuilt with an SYE added so I think the WJ front output is a flange style thar he converted to a yoke (don't quote me on that)

If there was anything I would do differently, is I would get a Tom Woods 242HD mainshaft, but I don't have the money for it though. There are a few reasons why:
1. It's a true slip yoke eliminator kit
2. It's shorter so it reduces pinion angle
3. (Most importantly) The rear output splines go all the way down to the bearing. the hack n tap done on mine only leaves about an inch of contact with the yoke. I seriously do not like how it is. All that work for an HD case and this is where it will break, in my opinion. If anything, the 242AMG mainshaft hack n tap would be better because the output splines go further down.

I almost did the 242AMG hack n tap but the mainshaft is another $100 shipped from Ebay, I had already had my HD mainshaft cut for the speedo collar, and I'm not 100% that it would fit. I'm like pretty sure it would fit, but I haven't physically checked because I don't have it, and both ebay sellers that currently have one will not accept returns, otherwise I probably would have done it. Really the main thing is if I'm going to to puroney out for the AMG mainshaft, I'm going to fork the money out for the Tom Woods mainshaft and know that it's shorter, thicker, proper, and probably has a warranty.

Anyways, I'm pleased with the build, just wished I had more money to do it how I would have wanted. But if I had the money to do it how I wanted, ideally I would have gotten a 242AMG, converted it to a traditional 242 shift pattern by adding 2wd, swapped out the mainshaft for the Tom Woods, installed the IRO SYE (I like the shape of it more than the Tom woods SYE) and plumbed in the oil cooler into the tramssion loop. Ideally, that's how I would have wanted it.

 

The reason why I went this route is a couple of reasons: mostly it was out of pure convenience that this specific case with the rebuild and the SYE already installed was being sold locally for CHEAP. The price of the HD was the price of the repair parts for the original J case. So between the two, I figured I would have 90% of a working case.

Turns out a when I got the HD case, the only reason why it wouldn't work is because the dude had the shift sensor screwed in too far and it wouldn't allow the shift sector to move, which wouldn't allow you to shift through the gears. I could have legitimately put this into my jeep day one.

The reason why that's how it was then and this is how it is now, well I kinda got carried away. A few bucks here, and a few ideas there, it kinda snowballed. I still spent less money than buying a used AMG case so I'm still below that figure.

Your right, I could have gone through the original case and done what everyone else has done, but one of the main driving factors that led me down this rabbit hole is one simple questions I kept asking myself: why hasn't anyone else done this before? I mean yes we all know the arguments about how 231's are more desired offroad than 242's. But like why has no one attempted to put a 242HD in a pre-96 XJ? I'm sure there has been people and I'm sure maybe somewhere it's been documented, but I have found little proof of it.

My whole build philosophy with this specific Jeep, is I want to venture off the beaten path and wildly modify while maintaining a OEM factory appearance, hence why I am building a 1996 Briarwood clone. Plenty of people can install LED headlights and a rough country lift and feel accomplished, but for me it rakes a little bit more dedication. I mean everything I see an otherwise decent looking XJ with the fenders cut, I automatically assume that guy is going through a midlife crisis.

Thank you for your admiration, the simple answer to your question is I just want to be different and I want to show others how I did it, in case if they want to so the same thing. And you never know, once I've done all I want to do, maybe the only thing left to do is to stroke out that poor 4.0 😁

Thanks for leaving your comment! sorry for the rant, I hope I answered your questions.

 

Gee and I just thought it was cause it is what we do.
Fix things that don't need fixing and upgrade things that really don't need upgrading.
LOL.

 

Yeah pretty much 🤣

 

Modifying my Jeep makes me happy. And I like to feel junkyard gucci. And this was $86 after tax.

​​​​​

 

That's the one! You should start your own thread, and I'll make sure to follow it! I can try me best to give tips and answer any questions. Also feel free to PM me

 

Thanks for answering my genuine questions, I certainly didnt want to offend someone who has gone to the trouble to prove something can be done, and shares that information

 

I'm just hoping to score a regular NP242 for my '99. I will go through it like you did though. I like the quality of your work!

 

No offense taken! 😁 I just like to do things as proper as possible

 

PM me if you need parts

 

Travis, can you confirm that a NP242J is what I need for my '99? Guy has this one for sale. It would be a drive so I'm not sure it's worth it. He is asking $100 for it.

 

So theres not enought information to know whether or not it will actually bolt up and function, but I do see some problems. There are different things that changed throughout the years. I know your characteristics, but there are some unknowns about the replacement. What it pulled from an XJ? What year was it pulled from? What's the input/output spline count? These are questions just to see if it will bolt up. There's still the problem with the front output being a flange instead of yoke, and the rear output housing doesn't have thee provision for the speed sensor. This article is a great NP242 source of changes throughout the years: https://www.naxja.org/forum/showthread.php?t=1138623 I have personally read the whole thing countless times when I first started asking questions about the 242HD swap. Now I don't have a 97+ so I only know so much. Let me know if you have any other questions.