How do I make this Rubicon Engineering SYE 242, a non SYE? - JeepForum.com
 
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post #1 of 12 Old 03-28-2020, 07:54 PM Thread Starter
8v-of-fury
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How do I make this Rubicon Engineering SYE 242, a non SYE?

So, the case itself was a good price and I need one BADLY. However it does have the SYE installed that doesnt work for me as I dont have that style of driveshaft.. nor do I require one. The 2" puck lift is all that I need out of this Jeep.

IT LOOKS like I will unbolt that "tail housing" from both and just swap the entire situation between the two cases eh??

As can be seen, my old case has had her day! If you grab the front shaft. And move its slack back and forth (there is a lot of it), you can slap the chain against the top and bottom of the case haha. And it is leaking every drop of fluid it has, and slinging it all over floorboard.

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'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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post #2 of 12 Old 03-28-2020, 08:27 PM
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I think you'll need to swap the mainshaft over from your old case to the new one. There were small changes to the mainshaft design over the years, so whether your old one is a direct install into the new one, I can't say for certain.You won't know for certain until you get both pulled out and inspect them. This requires a complete teardown of both cases.

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post #3 of 12 Old 03-28-2020, 10:16 PM Thread Starter
8v-of-fury
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Both transfer cases are of the same age, 98-99.

So hopefully they are identical. Haha

'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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post #4 of 12 Old 03-28-2020, 11:57 PM
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Probably are! Just have to hope that whatever's wrong with your 242 hasn't hurt the mainshaft - it's likely just the chain though. Mainshafts don't get damaged often unless you snap it.

1994 5.9L ZJ | IRO 5.5" CPLA | NP242 | 33" Cooper Discoverer STT Pro
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post #5 of 12 Old 03-29-2020, 12:33 AM
Timo_90xj
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Yeah, swap the mainshaft from the old case to the replacement case. Make sure the mainshaft from your original TC doesn't have pitting or (lack of) lubrication- related issues on it.

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post #6 of 12 Old 03-29-2020, 10:45 AM
1996maroonzjf
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Are both cases 231? I seem to remember from you other posts the one installed in your ZJ is a 242.

-Tim
(2) '96 4.0s
#1-'10-'18
#2- HP30/Ford 8.8 - 4.56, OME HDs, 5100's, IRO Adj Arms/Track Bars
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post #7 of 12 Old 03-29-2020, 11:44 AM
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Quote:
Originally Posted by 1996maroonzjf View Post
Are both cases 231? I seem to remember from you other posts the one installed in your ZJ is a 242.

They're both 242s.

1994 5.9L ZJ | IRO 5.5" CPLA | NP242 | 33" Cooper Discoverer STT Pro
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post #8 of 12 Old 03-29-2020, 01:46 PM Thread Starter
8v-of-fury
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Yes both 242, other than the SYE they appear identical.

My current 242 has a 97 build tag
This new 242 has a 99 build tag

'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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post #9 of 12 Old 03-29-2020, 08:07 PM
1996maroonzjf
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Sorry about that. Carry on -

-Tim
(2) '96 4.0s
#1-'10-'18
#2- HP30/Ford 8.8 - 4.56, OME HDs, 5100's, IRO Adj Arms/Track Bars
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post #10 of 12 Old 04-05-2020, 05:46 PM Thread Starter
8v-of-fury
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Doesn't appear that my output shaft took any damage, even though the pump ate itself! Haha

Gonna do new output shaft seals and bearings in the new case, but cant seem to find a part number for the output shaft seal for the back of the 42RE.. anyone got a number??
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'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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post #11 of 12 Old 04-07-2020, 09:32 PM Thread Starter
8v-of-fury
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Anyone familiar with the Rubicon Engineering SYE yoke?

How does it stay attached to the rear output shaft? This one had a washer welded on to the end if the shaft that I had to cut off. Lolol.but after removing that, I cant see how it would normally stay on either... there isnt anything to hold the yoke on.

Ps. Good news. My two output shafts are the same, and this un-conversion should work.
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20200407_163325_1586316675803.jpg   20200407_174122_1586316688199.jpg  

'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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post #12 of 12 Old 04-07-2020, 10:04 PM Thread Starter
8v-of-fury
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Oooh, I see.. This is the hack'n'tap method of adding a SYE..

I assume they busted off their bolt I nthe end of the output shaft and welded the washer on solid.. haha wow.

'98 ZJ 4.0/242, Locked d30/d35, 31x10.5x15, 2" BB w/ Bilstein 5100's
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