hi all, working on my 98 XJ 242 transfer case rebuild. I’m looking for a little help where these 2 clips and washer go on the rear output shaft when installing the rear cone housing. There are 3 grooves on this shaft. I believe one clip goes in the groove closest to the outer end of the shaft after the cone is installed. Not sue where the other clip or washer goes. Dummy me took some pics but didn’t get the clips and washer and it’s been apart to long to be sure.
looking online I see a few different output shafts and no pics of what I need.

Can anyone tell me where they go or point me to a good assembly manual?

Any help is very appreciated.

thanks, Joe

 

One of the snap rings is in relation to the pump ?under or over?, the other you are right goes on after the rear housing is isntalled with the outermost bearing.

The last full round idk atm, ill check my book in the morning though

 

Hi That Jeep Guy

i appreciate you checking. Yesterday I talked to Midwest transmission guy and he said the proper order
is the Cone housing then a snap ring then the seal then the other snap ring and the metal washer rides on the outside of the seal between the metal dust shield ( not pictured) and the seal.
there is room for a snap ring just above the outermost bearing when the cone is installed. That would be in the second groove from the end.
that would put the two lock rings on the outside of the cone. Memory is only one lock ring goes on after the cone. But it’s very possible I’m wrong.

Please let me know what your book says

thanks,
Joe

 

Numbers 11 and 81 are the same - snap rings. One goes on after the pump is installed and the other after the bearing in the rear tail housing. Your right on the spacer placement as well

 

Ok, Yes the two clips are identical. so one goes on before the tail shaft cone housing goes on and one goes on after the housing with bearing.
the only retaining grove between the pump and the housing would be the one right at the step over the Speedo gear.

thats what I think I remember, but looking at it. I don’t see what that clip is holding. So it’s not making sense to me, Below is a pic of a spare shaft I have.

tomorrow I will put the clip there and fit the housing to see if it fits right. Maybe it will make sense to me then.

thank you for your help,
Joe

 

Did this end up being the correct sequence?

 

Ray, I don’t believe so. I think the cone goes first, then the first snap ring then the seal then the last snap ring. The metal washer goes on before the dust shield

I am going to check the case that I take out of the Jeep to be sure. I may be changing them over this week. I will confirm what I find.

 

That sounds like what i did. I threw mine back together yesterday. After you get the cone on you have a snap ring on the outer race of the bearing. And that little retaining clip on the inner race. And the other after the seal.

 

I hope that’s right. I’ll update after I pull the old one.