[Tinman]

It is a mixture of parts from heavier duty cases with a standard one from what I can tell getting parts. For example getting a rebuild kit for a 242 with a 16mm wide input shaft bearing will not have the output bearing needed for a 32 spline shaft, which is a 6207, it comes with a 6206 which is smaller to fit the 27 spline shaft, only the WJ 4.7 case has this. It also has a pump that isn't even listed for a 242, it comes from the larger cases it seems. Had to send some pics of that to TPD to get the proper one. I do know the rear case half is a different part number as well, makes sense seeing the chain is wider as well.

Thanks for the info.. I’ve been looking for a clean 242HD to rebuild (wider chain, Sye, etc) seems it’s not 100% plug and play

 

[cDee63]

It is plug and play with the right parts. Get the rear driveshaft from the donor vehicle and the front if you do not already have a double cardan shaft and it will all bolt right in. I installed a SYE kit on mine hence the rebuild and the need for a new rear driveshaft, I am replacing the front as well because it has a ton of miles on it.

 

[Mr. Bitey]

I was laying underneath the rig enjoying the cold concrete on my back, hosing down misc rust and suspension hardware with penetrating oil and Stop Rust goo, and discovered my rear driveshaft had Zerks. I am going to assume that wasn't OEM, and a PO replaced them at some point in time. Thought for sure there were totally dry after the 6th pump, but by the 8th pump some spent black grease started pushing out of each. So they were probably near dry - yikes! I do carry one U-Joint with straps and hardware in my tool/parts kit, but with there being next to zero play and now packed with fresh goop, I am betting I won't need it, at least on the rear DS. If the front DS were to fail, it will probably just get removed at least until I decide if I am rebuilding the front diff with the floppy pinion....

 

[toku58]

I was laying underneath the rig enjoying the cold concrete on my back, hosing down misc rust and suspension hardware with penetrating oil and Stop Rust goo, and discovered my rear driveshaft had Zerks. I am going to assume that wasn't OEM, and a PO replaced them at some point in time. Thought for sure there were totally dry after the 6th pump, but by the 8th pump some spent black grease started pushing out of each. So they were probably near dry - yikes! I do carry one U-Joint with straps and hardware in my tool/parts kit, but with there being next to zero play and now packed with fresh goop, I am betting I won't need it, at least on the rear DS. If the front DS were to fail, it will probably just get removed at least until I decide if I am rebuilding the front diff with the floppy pinion....

Here's some spicer universals for the front if you ever decide to rebuild them.

https://amzn.to/3ZqMIPG

 

[Mr. Bitey]

spicer universals

Bookmarked. Thanks!

 

[RowdyWJ]

My DIY Recessed winch bumper progress. Got a winch from a local Jeep group, pics are how tight I got it in there. I don't plan to, but I can certainly put the OEM bumper back on if I needed to. Made washer plates inside the unibody frame rails. It's getting there.

 

[cDee63]

Got the transfer case put back together and....it doesn't @!%$#!! shift properly. Like I just said, @!%$#!!

 

[Tinman]

Got the transfer case put back together and....it doesn't @!%$#!! shift properly. Like I just said, @!%$#!!

Bummer, you got to hate it when this happens…

 

[cDee63]

5:30 am and I am out in the garage taking apart this case again and I found the issue. It seems when wrestling it around on the bench the input shaft got pushed in a bit in the bearing, enough to keep the mode sleeve and range sleeve out of synch with the splines in the planetary and diff but not enough to keep it from going together. In hindsight I should have known this by the oil pump sitting a bit high to the case, I noticed it but not having a reference I didn't realize the main shaft was not seated completely. Took it back apart, got everything where it should be and now it shifts in all ranges.

 

[toku58]

5:30 am and I am out in the garage taking apart this case again and I found the issue. It seems when wrestling it around on the bench the input shaft got pushed in a bit in the bearing, enough to keep the mode sleeve and range sleeve out of synch with the splines in the planetary and diff but not enough to keep it from going together. In hindsight I should have known this by the oil pump sitting a bit high to the case, I noticed it but not having a reference I didn't realize the main shaft was not seated completely. Took it back apart, got everything where it should be and now it shifts in all ranges.

How did the input shaft get pushed in? Did you forget to install the clip on the input shaft?
Normally when the oil pump sits high it's a case of the selector gear being installed upside down on the fork.

 

[cDee63]

The snap ring keeps the bearing in the retainer as far as I can tell, in this case the input shaft moved within the bearing bore itself before I had it put together. After checking the parts I took out and replaced along with the parts illustration I see no extras as far as snap rings, all replaced are accounted for. Correct me if I am wrong, which does happen with alarming frequency, the input shaft is a light press fit to the input bearing and the whole mess is captured when assembled. When I pushed the input shaft completely in the bearing and reassembled the mainshaft and pump it sits right on the case now, as before it was about an 1/4" proud of the case.

 

[Mr. Bitey]

Correct me if I am wrong, which does happen with alarming frequency

Correct me if I am wrong, but age is directly proportional to frequency of all sorts of things I never imagined. I wish I could go back in time and slap a young dumb me in the face every time I said "I can't wait to be all grown up. Grown ups have it sooooo easy" sigh

 

[jere692011]

My DIY Recessed winch bumper progress. Got a winch from a local Jeep group, pics are how tight I got it in there. I don't plan to, but I can certainly put the OEM bumper back on if I needed to. Made washer plates inside the unibody frame rails. It's getting there.
View attachment 4178285
View attachment 4178283

I love the work you have done here. Looks great.

 

[toku58]

The snap ring keeps the bearing in the retainer as far as I can tell, in this case the input shaft moved within the bearing bore itself before I had it put together. After checking the parts I took out and replaced along with the parts illustration I see no extras as far as snap rings, all replaced are accounted for. Correct me if I am wrong, which does happen with alarming frequency, the input shaft is a light press fit to the input bearing and the whole mess is captured when assembled. When I pushed the input shaft completely in the bearing and reassembled the mainshaft and pump it sits right on the case now, as before it was about an 1/4" proud of the case.

There are 2 snap rings. One keeps the bearing in the housing and the other keeps the input shaft in the bearing.

 

[cDee63]

Where exactly is this snap ring? I ask because my exploded view shows one holding the bearing in the retainer and the next one in line holds the planetary and thrust washers in place.

 

[cDee63]

There are 2 snap rings. One keeps the bearing in the housing and the other keeps the input shaft in the bearing.

Sir, I thank you! I got to thinking, I never did trust most drawings so I went out and pulled the retainer off and what do I see, a snap ring groove, just like you said. If I was a drinking man I would buy you a beer or two, you saved me a lot of grief. Again, thank you!

 

[WJ60]

We'll just chalk it up to a rookie mistake (this time). LOL

 

[cDee63]

That's just it, not a rookie. Not even close. In my defense I haven't done a transfer case in probably 20 years, the last being a Dana 300. The rookie mistake I DID make was taking it apart and then leaving it in boxes for a couple of years. I know better than that, I should have just left it assembled. But hey, even an old dog can learn new stuff. Or in this case, remember the old stuff lol.

 

[toku58]

Sir, I thank you! I got to thinking, I never did trust most drawings so I went out and pulled the retainer off and what do I see, a snap ring groove, just like you said. If I was a drinking man I would buy you a beer or two, you saved me a lot of grief. Again, thank you! View attachment 4178378

Glad I could help. Glad you didn't run it like that. Might have been very bad.
Have a Great Day!

 

[cDee63]

And here is the finished product. Again many thanks to toku58 for setting this old dog straight!