242 Transfer Case Leaking Where 2 Halves Join - JeepForum.com
 
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post #1 of 9 Old 08-25-2009, 03:47 PM Thread Starter
indianajeep
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242 Transfer Case Leaking Where 2 Halves Join

My 242 transfer case is leaking where the 2 halves bolt together on the bottom. I really don't want to take the tfr case down, split the halves and put new sealant on it. Crap - 5 hours worth of gut busting work for $1.50 worth of sealant. Does anyone know of a reliable work-around for this problem?

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post #2 of 9 Old 08-25-2009, 03:52 PM
Virmagicus
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It's not coming from above and running down right? If it is leaking from around the inside of the bolt you can remove the bolt and squirt some RTV in and put the bolt back in. Not really any other way to fix it besides grinding and welding if it is leaking from the break in the case half.
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post #3 of 9 Old 08-25-2009, 04:41 PM
skain8
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No band-aid fix for that one. Longshot, but see if any of the main case bolts have worked themselves loose.

'02 WJ: 4.7L, 5", HP44/9", 231HD, tall & skinny KM2's
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post #4 of 9 Old 08-25-2009, 04:54 PM
WhiteOut
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DUCT TAPE FTW!! If its actually coming from the joint the best fix would be to reseal, but try doing the bolt fix first.
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post #5 of 9 Old 08-25-2009, 04:58 PM
blackjack12982
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Pffftt! The fix is give it to me! I could use another Jeep in the driveway!
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post #6 of 9 Old 08-25-2009, 05:00 PM
ArloGuthroJeep
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You don't need to drop the case to fix this. Remove the rear drive shaft. Then a dozen bolts and a set of snap ring and retainer ring pliers and everything pulls apart.

'04 WJ, 6" Clayton LA's, 242 SYE, 35" BFG MT KM2's, 4.56 gears, & D44a locked
'14 WK2 Limited w/5.7L, ORAI, & Tow Package
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post #7 of 9 Old 08-25-2009, 08:09 PM
sandman
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yep the rear half of the case can be removed with the t-case still bolted up.

1993 Jeep ZJ. 4.0
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post #8 of 9 Old 08-25-2009, 08:37 PM Thread Starter
indianajeep
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how many snap rings have to be removed and are they on the rear output shaft?
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post #9 of 9 Old 08-25-2009, 09:04 PM
ArloGuthroJeep
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I did it a couple months ago...I believe it was 1 snap ring and one retaining ring...they are on the output shaft.

'04 WJ, 6" Clayton LA's, 242 SYE, 35" BFG MT KM2's, 4.56 gears, & D44a locked
'14 WK2 Limited w/5.7L, ORAI, & Tow Package
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