Transfer Case Blender - JeepForum.com
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post #1 of 5 Old 03-06-2020, 11:29 AM Thread Starter
BilletHorse
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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?

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post #2 of 5 Old 03-06-2020, 12:06 PM
1996maroonzjf
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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.
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-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 #3 of 5 Old 03-06-2020, 01:39 PM
Timo_90xj
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^- 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,...


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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***
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post #4 of 5 Old 03-06-2020, 03:06 PM Thread Starter
BilletHorse
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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.
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post #5 of 5 Old 03-08-2020, 09:42 PM
Maverickxeo
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These jeep cases are so simple and cheap to rebuild. I agree with rebuilding.
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