NP242 tutorial - JeepForum.com

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post #1 of 85 Old 04-29-2009, 05:22 PM Thread Starter
baxy
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NP242 tutorial

should I post pics of a complete reseal I did today on an NP242?
I dont have premium membership so I cant post it in the technical area

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post #2 of 85 Old 04-29-2009, 05:28 PM
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pics pics pics..you can post you have over 50 posts.......upload them to photobucket and use [img] tags.

www.desert-hooligans.webs.com


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post #3 of 85 Old 04-29-2009, 05:30 PM Thread Starter
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1998 JGC 4.0 typical NP242 tcase
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post #4 of 85 Old 04-29-2009, 05:31 PM Thread Starter
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remove speed sensor and tin seal protector from output shaft
remove washer and first snap ring
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post #5 of 85 Old 04-29-2009, 05:33 PM Thread Starter
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remove seal and second snap ring under seal
remove bolts holding rear extension housing on
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post #6 of 85 Old 04-29-2009, 05:34 PM
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THOSE F-IN LOCKRINGS HAVE MADE MY LIFE HELL WITH THAT 242
/rant

- John - 23 and learning <-- ORIGINAL
- 1996 Black ZJ Limited: 5.9 swap, LA's, axles, absolutely built to hell
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post #7 of 85 Old 04-29-2009, 05:49 PM Thread Starter
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remove extension houseing by tapping on raised pieces carefully it can be tight

remove bolts holding case halves together , tap apart look around the edges there are slots to wedge a screw driver into
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post #8 of 85 Old 04-29-2009, 05:50 PM Thread Starter
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Quote:
Originally Posted by BLACKzj52 View Post
THOSE F-IN LOCKRINGS HAVE MADE MY LIFE HELL WITH THAT 242
/rant

lots of time I find them upside down which makes them really hard to remove
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post #9 of 85 Old 04-29-2009, 05:52 PM Thread Starter
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remove snap rings holding sprockets to shafts.... note the sprockets are different and only go up one way

chain and sprockets removed main shaft removed just pull straight up

ok pry indetween shift fork and rooster comb to get the first shift fork out sorry I didnt get a pic
it will take alot of pressure but it will come
I know the proper way is to remove the roll pin but I end up fiddling around forever and sometimes cant get it out
after you get the first one out you can just rotate the rooster comb up and wiggle out the inner shift fork
then remove the roll pin and we will assemble it according to the manual
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post #10 of 85 Old 04-29-2009, 05:56 PM Thread Starter
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remove input seal retainer and inner snap ring on input shaft
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post #11 of 85 Old 04-29-2009, 05:58 PM Thread Starter
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remove input shaft and tap out input bearing
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post #12 of 85 Old 04-29-2009, 06:01 PM
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Quote:
Originally Posted by baxy View Post
lots of time I find them upside down which makes them really hard to remove
i can deal with that, but mine warped and got weak, so when they were in the little grooves they slip into, they spun around. this let my tailshaft move forward and backward and at highway speeds this blows ur seal.
believe me, iv been through 5 of those dam seals already. i got some new rings from the dealer tho so this friday im gonna tackle is and see if it holds.
if not im putting a hammer through the sob

- John - 23 and learning <-- ORIGINAL
- 1996 Black ZJ Limited: 5.9 swap, LA's, axles, absolutely built to hell
- 1998 Platinum 5.9 Limited: DD with some lighter modifications
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post #13 of 85 Old 04-29-2009, 06:02 PM Thread Starter
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remove the shifter detent and the range switch

wiggle out rooster comb it only will come out one way
save the oring and plastic ring that comes out the other side
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post #14 of 85 Old 04-29-2009, 06:04 PM Thread Starter
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Quote:
Originally Posted by BLACKzj52 View Post
i can deal with that, but mine warped and got weak, so when they were in the little grooves they slip into, they spun around. this let my tailshaft move forward and backward and at highway speeds this blows ur seal.
believe me, iv been through 5 of those dam seals already. i got some new rings from the dealer tho so this friday im gonna tackle is and see if it holds.
if not im putting a hammer through the sob

take your stock snap ring to a bearing supplier and match it up with the snap rings that have the two eyelets they are a far superior ring we change them up all the time it is actually the fix for the NP241 output shaft snap ring failure
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post #15 of 85 Old 04-29-2009, 06:06 PM Thread Starter
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ok before we start re assembly lets change the trans output seal


remove the seal
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