[Okiejeep07]

Have a 99 WJ, I6 160,000+miles with NP242 transfer case and I have a small leak. I believe I've traced the leak to the "Sector O-ring and Seal" on the inside of "Shift Lever". I've read that this can be overlooked when determining the location of the leak.

Question, can I get to the ring and seal via removing the "shift lever washer and nut"? Or do I have to remove the Front Case because they are inside?

Thought I'd ask before I start tearing into it.

Oh yeah!!! Forgot to ask! In addition, I noticed that the Shifter Cable from that connects to the "Shift Lever" on the T-case was just hanging there!?!
Learned I'm missing the plastic piece that holds the cable to the lever arm.

Do you know if the plastic cap just snaps on the "Shift Lever" or what because I'm going to have to go to the junk yard and get one and was wondering how to pull, pry or what when I find one?

Thanks.

[baxy]

most of the time the leak you are discribing is a missing seal grommet in the side of the case right by the shift shaft it seals the pin that holds the shifter in place

[Okiejeep07]

Everything looks like its there, nothing missing. Referred to the maintenance manual and thought it might be the the seal that is leaking.

Never thought that particular seal would leak?

[baxy]

is there a hole plugged with a little rubber thing or just a hole in by the shifter ??

[Okiejeep07]

There is a hole and in the hole sit the "Shift Selector" which is in the inside of the case. The shaft that connects the cable goes through the hole and out the other side of the t-case where the shift cable attaches. If I'm not mistaken, the o-ring and seal are on the out side of the case on the shaft?

[baxy]

ok cause most 242 cases have a hole where a role pin goes and that hole needs to be plugged with a rubber grommet

maybe you could post a pic of your leak

[Okiejeep07]

Ok, I've got a pic that I'll try to post. You'll have to bare with me I've never used a host website for posting pics, I'm still learning. But let me see what I can do.

[Okiejeep07]

Ok, I think I've got.

Let me know if you can see these.

Photo with the pencil is looking up at the bottom of the "Selector Lever". I cleaned the area up but notice there is a little fluid coming out of the whole.

Second photo is the cable with out the clip.


http://s600.photobucket.com/albums/t...lotman09_2009/

Sorry, the photos are not in order to how I described them. My bad...

[Okiejeep07]

I know it doesn't look bad at all. But when I came back from a camping trip I noticed a little puddle and fluid on the drive way and fluid that had sprayed on the back of my differential and axel. That has never happened before, so I searched to see what was going on and one thing led to another to fix this problem. Especially after I noticed the cable not being secured!

[baxy]

ok the manual shows a narrow bushing and O=ring on the shaft .. possibly you could remove that lever pick out the old pieces and lube up and install a new o-ring and bushing without removing and totally disasembling tcase

[baxy]

hope this pic worked

[Okiejeep07]

I agree. My Haynes doesn't really explain it at all or show a good diagram but the more I look at how it's built and works, I'm sure that those parts are on the outside. Well I'm on my way to the garage to take a stab at this.

[baxy]

order the parts first

[Okiejeep07]

Great diagram you found! Yep that's it! Without a doubt I'll get the parts first before I take it apart. Thankfully there is a stealership 1/2 mile from home. About $7 bucks for both parts which is not too bad. Of course those are the internet prices, so I'm sure the dealership will be triple.

baxy, I really appreciate your interest in helping me.

I'll let you know if your interested on the outcome.

[baxy]

just be careful you dont nick the o-ring putting it over the shift shaft lube it with petroleum jelly first , spray out the cavity with brake parts cleaner as well