Transfer Case Blender -
  • 1 Post By 1996maroonzjf
LinkBack Thread Tools
post #1 of 5 Old 03-06-2020, 11:29 AM Thread Starter
Registered User
2002 WJ 
Join Date: Feb 2007
Location: Zuzax, NM
Posts: 116
Transfer Case Blender

My 1995 ZJ transfer case is about to turn into oily slag, but I am having a hard time finding another 242 (j or otherwise) in the boneyard.

Has anyone rebuilt a 242j and is it worth it?

BilletHorse is offline  
Sponsored Links
post #2 of 5 Old 03-06-2020, 12:06 PM
Registered User
1996maroonzjf's Avatar
1996 ZJ 
Join Date: Apr 2010
Location: Denver
Posts: 1,062
I have. It's a lot easier than you would think, compared to a transmission or engine at least.

Get a really good set of snap ring pliers and retaining ring pliers - don't skimp on these. You don't need snap-on but better than harbor freight - I used Lisle brand and Channel lock brand.
Get replacement plastic shift fork inserts (bushings) the rebuild kits don't come with them. Also you will need to rent / buy a pilot bearing puller to get one of the bearings out.

As far as it being worth it, that would depend on use case. The 242 is weaker than a 231 or 249, but for a stock 4.0 you should have no issues. I personally like the 4 wheel full-time setting but I will be ditching the 242 for a beefed up 231 when I build a stroker.
Timo_90xj likes this.

(2) '96 4.0s
#2- HP30/Ford 8.8 - 4.56, OME HDs, 5100's, IRO Adj Arms/Track Bars
1996maroonzjf is offline  
post #3 of 5 Old 03-06-2020, 01:39 PM
Web Wheeler
Timo_90xj's Avatar
1998 ZJ 
Join Date: Mar 2006
Location: Helsinki, Finland - on the European side of the Atlantic
Posts: 10,301
^- agree 100% on the above.

I rebuilt my 242 - as long as you have good tools it's a no-brainer. It's way more work to get the TC out of the Jeep and back in than it is to do the actual rebuild.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
Timo_90xj is offline  
post #4 of 5 Old 03-06-2020, 03:06 PM Thread Starter
Registered User
2002 WJ 
Join Date: Feb 2007
Location: Zuzax, NM
Posts: 116
I probably shelled the planetaries in the AWD unit. The Jeep started vibrating, ruled out u-joints. Got to the point that I would have to put it in AWD to be able to drive it on the freeway, but no vibration was coming through the 4WD shift handle, assumed it was the carrier bearings in the front diff. Replaced it with a Junkyard part, no difference at all. Grrrr.
So I guess it has to be the transfer case.
BilletHorse is offline  
post #5 of 5 Old 03-08-2020, 09:42 PM
Registered User
Maverickxeo's Avatar
2002 TJ Wrangler 
Join Date: Jan 2010
Location: Wetaskiwin
Posts: 2,615
These jeep cases are so simple and cheap to rebuild. I agree with rebuilding.
Maverickxeo is offline  

Quick Reply

Register Now

In order to be able to post messages on the forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome