DougW

Just remember when you split the case, only pry at the places where
the case has been built up. You will see the big blocks of aluminum
and pry groove. Prying anywhere else is asking to crack the case.

If teeth are gone or the chain is shot you might be better off buying
a rebuilt unit or searching the junk yards. Unless you like to work
on transfer cases that is. Some places in those you will need a press
if you break them far enough apart.

Price the factory unit here. http://www.chryslerpartsdirect.com/

You could change cases but understand that takes working out the links
and the little inside fiddly bits.

--
DougW

Chevrolet

too bad he wasn't in ontario..I have a complete tranny / transfer case with
slave cyl.. drop and go setup with all sensors included..My frame went in my
yj so I parted it out.. this is all I have left.. good luck with the swap..
I hate changing transfer cases...
Just a word of thought.. while your in there... change the clutch.. not
much more work once you get in there.. save a headache later on... nothing
worse then changin one thing and another blows apart a week later..
"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
news:Hlxxg.7834$D%4.14@tornado.rdc-kc.rr.com...
> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2
> revolutions of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has
> a segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that
> with the 'easy jobs' there is always that 1 bolt that wants to strip or
> snap (in fact removing the front drive shaft ALMOST turned into a mess,
> save for some PB Blaster, a torch and a pair of vise grips). I will take
> it in to a local shop that was recommended by people I trust, and with an
> education as to what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>> Earle Horton wrote:
>>> You would have to disassemble the entire transfer case. It depends on
>>> how
>>> comfortable you are around planetary gear assemblies, shafts, bearings,
>>> and
>>> chains. Some people can rip right into one of these things, tell you
>>> what
>>> is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>> From what you have said, the growl originates inside the transfer case,
>>> and
>>> most people would call this a "difficult fix". I haven't had this
>>> particular model apart, but if it were mine I would probably be
>>> ambitious/dumb enough to try fixing it myself.
>>>
>>> Earle
>>>
>>> "paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>> news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>> let
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke,
>>>>>from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>> that
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>> so
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>> of
>>>
>>>>>a
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>> and
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>> wheel
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>> in
>>>
>>>>>the
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>> heard
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>> mph
>>>
>>>>>and
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>> does
>>>
>>>>>not
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>> noise.
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>
>>>>>>
>>>>>
>>>>
>>>
>

Chevrolet

too bad he wasn't in ontario..I have a complete tranny / transfer case with
slave cyl.. drop and go setup with all sensors included..My frame went in my
yj so I parted it out.. this is all I have left.. good luck with the swap..
I hate changing transfer cases...
Just a word of thought.. while your in there... change the clutch.. not
much more work once you get in there.. save a headache later on... nothing
worse then changin one thing and another blows apart a week later..
"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
news:Hlxxg.7834$D%4.14@tornado.rdc-kc.rr.com...
> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2
> revolutions of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has
> a segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that
> with the 'easy jobs' there is always that 1 bolt that wants to strip or
> snap (in fact removing the front drive shaft ALMOST turned into a mess,
> save for some PB Blaster, a torch and a pair of vise grips). I will take
> it in to a local shop that was recommended by people I trust, and with an
> education as to what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>> Earle Horton wrote:
>>> You would have to disassemble the entire transfer case. It depends on
>>> how
>>> comfortable you are around planetary gear assemblies, shafts, bearings,
>>> and
>>> chains. Some people can rip right into one of these things, tell you
>>> what
>>> is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>> From what you have said, the growl originates inside the transfer case,
>>> and
>>> most people would call this a "difficult fix". I haven't had this
>>> particular model apart, but if it were mine I would probably be
>>> ambitious/dumb enough to try fixing it myself.
>>>
>>> Earle
>>>
>>> "paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>> news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>> let
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke,
>>>>>from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>> that
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>> so
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>> of
>>>
>>>>>a
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>> and
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>> wheel
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>> in
>>>
>>>>>the
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>> heard
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>> mph
>>>
>>>>>and
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>> does
>>>
>>>>>not
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>> noise.
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>
>>>>>>
>>>>>
>>>>
>>>
>

Chevrolet

too bad he wasn't in ontario..I have a complete tranny / transfer case with
slave cyl.. drop and go setup with all sensors included..My frame went in my
yj so I parted it out.. this is all I have left.. good luck with the swap..
I hate changing transfer cases...
Just a word of thought.. while your in there... change the clutch.. not
much more work once you get in there.. save a headache later on... nothing
worse then changin one thing and another blows apart a week later..
"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
news:Hlxxg.7834$D%4.14@tornado.rdc-kc.rr.com...
> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2
> revolutions of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has
> a segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that
> with the 'easy jobs' there is always that 1 bolt that wants to strip or
> snap (in fact removing the front drive shaft ALMOST turned into a mess,
> save for some PB Blaster, a torch and a pair of vise grips). I will take
> it in to a local shop that was recommended by people I trust, and with an
> education as to what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>> Earle Horton wrote:
>>> You would have to disassemble the entire transfer case. It depends on
>>> how
>>> comfortable you are around planetary gear assemblies, shafts, bearings,
>>> and
>>> chains. Some people can rip right into one of these things, tell you
>>> what
>>> is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>> From what you have said, the growl originates inside the transfer case,
>>> and
>>> most people would call this a "difficult fix". I haven't had this
>>> particular model apart, but if it were mine I would probably be
>>> ambitious/dumb enough to try fixing it myself.
>>>
>>> Earle
>>>
>>> "paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>> news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>> let
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke,
>>>>>from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>> that
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>> so
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>> of
>>>
>>>>>a
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>> and
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>> wheel
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>> in
>>>
>>>>>the
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>> heard
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>> mph
>>>
>>>>>and
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>> does
>>>
>>>>>not
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>> noise.
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>
>>>>>>
>>>>>
>>>>
>>>
>

Chevrolet

too bad he wasn't in ontario..I have a complete tranny / transfer case with
slave cyl.. drop and go setup with all sensors included..My frame went in my
yj so I parted it out.. this is all I have left.. good luck with the swap..
I hate changing transfer cases...
Just a word of thought.. while your in there... change the clutch.. not
much more work once you get in there.. save a headache later on... nothing
worse then changin one thing and another blows apart a week later..
"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
news:Hlxxg.7834$D%4.14@tornado.rdc-kc.rr.com...
> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2
> revolutions of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has
> a segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that
> with the 'easy jobs' there is always that 1 bolt that wants to strip or
> snap (in fact removing the front drive shaft ALMOST turned into a mess,
> save for some PB Blaster, a torch and a pair of vise grips). I will take
> it in to a local shop that was recommended by people I trust, and with an
> education as to what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>> Earle Horton wrote:
>>> You would have to disassemble the entire transfer case. It depends on
>>> how
>>> comfortable you are around planetary gear assemblies, shafts, bearings,
>>> and
>>> chains. Some people can rip right into one of these things, tell you
>>> what
>>> is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>> From what you have said, the growl originates inside the transfer case,
>>> and
>>> most people would call this a "difficult fix". I haven't had this
>>> particular model apart, but if it were mine I would probably be
>>> ambitious/dumb enough to try fixing it myself.
>>>
>>> Earle
>>>
>>> "paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>> news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>> let
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke,
>>>>>from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>> that
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>> so
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>> of
>>>
>>>>>a
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>> and
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>> wheel
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>> in
>>>
>>>>>the
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>> heard
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>> mph
>>>
>>>>>and
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>> does
>>>
>>>>>not
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>> noise.
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>
>>>>>>
>>>>>
>>>>
>>>
>

RoyJ

Just for a $$$ calibration, here is a price list for rebuilt transfer
cases.
http://www.transfercases.com/order.htm

I just did a new chain on my 231 for $125 including chain, 1 seal, new
shift plastic pieces, loctite, and sealant. Took longer to clean it than
to fix it. The only 'gotcha' is finding and removing a well hidden snap
ring holding the tailshaft bearing on the rear shaft.

Mine was out of service for a week while I got the parts then waited for
some relief from the very hot weather. Had to use the other truck with
the A/C.

paul wrote:

> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2 revolutions
> of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has a
> segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that with
> the 'easy jobs' there is always that 1 bolt that wants to strip or snap (in
> fact removing the front drive shaft ALMOST turned into a mess, save for some
> PB Blaster, a torch and a pair of vise grips). I will take it in to a local
> shop that was recommended by people I trust, and with an education as to
> what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>>Earle Horton wrote:
>>
>>>You would have to disassemble the entire transfer case. It depends on
>>>how
>>>comfortable you are around planetary gear assemblies, shafts, bearings,
>>>and
>>>chains. Some people can rip right into one of these things, tell you
>>>what
>>>is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>>From what you have said, the growl originates inside the transfer case,
>>>and
>>>most people would call this a "difficult fix". I haven't had this
>>>particular model apart, but if it were mine I would probably be
>>>ambitious/dumb enough to try fixing it myself.
>>>
>>>Earle
>>>
>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>>let
>>>
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke, from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>>that
>>>
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>>so
>>>
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>>of
>>>
>>>
>>>>>a
>>>>>
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>>and
>>>
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>>wheel
>>>
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>>in
>>>
>>>
>>>>>the
>>>>>
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>>heard
>>>
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>>mph
>>>
>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>>does
>>>
>>>
>>>>>not
>>>>>
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>>noise.
>>>
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>

RoyJ

Just for a $$$ calibration, here is a price list for rebuilt transfer
cases.
http://www.transfercases.com/order.htm

I just did a new chain on my 231 for $125 including chain, 1 seal, new
shift plastic pieces, loctite, and sealant. Took longer to clean it than
to fix it. The only 'gotcha' is finding and removing a well hidden snap
ring holding the tailshaft bearing on the rear shaft.

Mine was out of service for a week while I got the parts then waited for
some relief from the very hot weather. Had to use the other truck with
the A/C.

paul wrote:

> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2 revolutions
> of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has a
> segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that with
> the 'easy jobs' there is always that 1 bolt that wants to strip or snap (in
> fact removing the front drive shaft ALMOST turned into a mess, save for some
> PB Blaster, a torch and a pair of vise grips). I will take it in to a local
> shop that was recommended by people I trust, and with an education as to
> what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>>Earle Horton wrote:
>>
>>>You would have to disassemble the entire transfer case. It depends on
>>>how
>>>comfortable you are around planetary gear assemblies, shafts, bearings,
>>>and
>>>chains. Some people can rip right into one of these things, tell you
>>>what
>>>is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>>From what you have said, the growl originates inside the transfer case,
>>>and
>>>most people would call this a "difficult fix". I haven't had this
>>>particular model apart, but if it were mine I would probably be
>>>ambitious/dumb enough to try fixing it myself.
>>>
>>>Earle
>>>
>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>>let
>>>
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke, from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>>that
>>>
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>>so
>>>
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>>of
>>>
>>>
>>>>>a
>>>>>
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>>and
>>>
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>>wheel
>>>
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>>in
>>>
>>>
>>>>>the
>>>>>
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>>heard
>>>
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>>mph
>>>
>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>>does
>>>
>>>
>>>>>not
>>>>>
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>>noise.
>>>
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>

RoyJ

Just for a $$$ calibration, here is a price list for rebuilt transfer
cases.
http://www.transfercases.com/order.htm

I just did a new chain on my 231 for $125 including chain, 1 seal, new
shift plastic pieces, loctite, and sealant. Took longer to clean it than
to fix it. The only 'gotcha' is finding and removing a well hidden snap
ring holding the tailshaft bearing on the rear shaft.

Mine was out of service for a week while I got the parts then waited for
some relief from the very hot weather. Had to use the other truck with
the A/C.

paul wrote:

> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2 revolutions
> of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has a
> segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that with
> the 'easy jobs' there is always that 1 bolt that wants to strip or snap (in
> fact removing the front drive shaft ALMOST turned into a mess, save for some
> PB Blaster, a torch and a pair of vise grips). I will take it in to a local
> shop that was recommended by people I trust, and with an education as to
> what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>>Earle Horton wrote:
>>
>>>You would have to disassemble the entire transfer case. It depends on
>>>how
>>>comfortable you are around planetary gear assemblies, shafts, bearings,
>>>and
>>>chains. Some people can rip right into one of these things, tell you
>>>what
>>>is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>>From what you have said, the growl originates inside the transfer case,
>>>and
>>>most people would call this a "difficult fix". I haven't had this
>>>particular model apart, but if it were mine I would probably be
>>>ambitious/dumb enough to try fixing it myself.
>>>
>>>Earle
>>>
>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>>let
>>>
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke, from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>>that
>>>
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>>so
>>>
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>>of
>>>
>>>
>>>>>a
>>>>>
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>>and
>>>
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>>wheel
>>>
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>>in
>>>
>>>
>>>>>the
>>>>>
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>>heard
>>>
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>>mph
>>>
>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>>does
>>>
>>>
>>>>>not
>>>>>
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>>noise.
>>>
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>

RoyJ

Just for a $$$ calibration, here is a price list for rebuilt transfer
cases.
http://www.transfercases.com/order.htm

I just did a new chain on my 231 for $125 including chain, 1 seal, new
shift plastic pieces, loctite, and sealant. Took longer to clean it than
to fix it. The only 'gotcha' is finding and removing a well hidden snap
ring holding the tailshaft bearing on the rear shaft.

Mine was out of service for a week while I got the parts then waited for
some relief from the very hot weather. Had to use the other truck with
the A/C.

paul wrote:

> Gentlemen,
> Thanks for all the input,,, here is what I have found with further
> inspection.
>
> Bearing on the front output feels good.
> There is a noticeable 'clanky/crunchy' sound that occurs every 2 revolutions
> of the front output yoke.
>
> This leads me to wish full thinking and believing that the drive chain has a
> segment that is broke and everytime it comes around it is 'clanking/
> crunching'. Hopefully not too much dinero ($).
>
> I believe I could do this myself if I had the time, my concern is that with
> the 'easy jobs' there is always that 1 bolt that wants to strip or snap (in
> fact removing the front drive shaft ALMOST turned into a mess, save for some
> PB Blaster, a torch and a pair of vise grips). I will take it in to a local
> shop that was recommended by people I trust, and with an education as to
> what may be wrong.
>
> Plus the fact that if I don't get my wife's jeep back in order fast, she
> will keep driving my YJ and taxiing me around,,,,, I don't like to be away
> from my jeep for long periods of time.
>
> thanks again!
> paul
>
>
> "RoyJ" <spamless@microsoft.net> wrote in message
> news:47vxg.4605$bP5.2213@newsread1.news.pas.earthl ink.net...
>
>>I just had my NP231 apart for a new chain and general cleanup. Not much
>>more than to it than take it apart, clean, and reassemble. The 242 is very
>>similar except for the addition of the differential assembly hung on the
>>shaft instead of the synchro assembly.
>>
>>Earle Horton wrote:
>>
>>>You would have to disassemble the entire transfer case. It depends on
>>>how
>>>comfortable you are around planetary gear assemblies, shafts, bearings,
>>>and
>>>chains. Some people can rip right into one of these things, tell you
>>>what
>>>is wrong, and have a parts list ready in an hour, two on a slow day.
>>>
>>>From what you have said, the growl originates inside the transfer case,
>>>and
>>>most people would call this a "difficult fix". I haven't had this
>>>particular model apart, but if it were mine I would probably be
>>>ambitious/dumb enough to try fixing it myself.
>>>
>>>Earle
>>>
>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>news:ndsxg.949$zg.119@tornado.rdc-kc.rr.com...
>>>
>>>
>>>>Thanks Earle, I will check for a bad bearing this evening after work and
>>>
>>>let
>>>
>>>
>>>>you know.
>>>>
>>>>Is the interaxle a difficult fix?
>>>>
>>>>thanks
>>>>paul
>>>>
>>>>"Earle Horton" <earle-NOSPAM-horton@msn.com> wrote in message
>>>>news:44c58a05$0$23772$a82e2bb9@reader.athenane ws.com...
>>>>
>>>>
>>>>>What happens when you manually turn the front output shaft or yoke, from
>>>>>underneath the vehicle, with the TC in 2H? If you have a bad bearing
>>>>>there,
>>>>>you should be able to feel it. There may be play too. If not, then
>>>
>>>that
>>>
>>>
>>>>>points to your interaxle differential, internal to the transfer case.
>>>>>
>>>>>Earle
>>>>>
>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>news:O_exg.916$zg.615@tornado.rdc-kc.rr.com...
>>>>>
>>>>>
>>>>>>OK,
>>>>>>I removed the front drive shaft and the sounds was gone!!!!
>>>>>>BUT
>>>>>>if I put the transfer case into 4 wheel drive the sound returns.......
>>>
>>>so
>>>
>>>
>>>>>>I'm thinking that something to do with the front output???
>>>>>>
>>>>>>For what it's worth, last winter when shifting into 4 wheel full time
>>>>>
>>>>>(this
>>>>>
>>>>>
>>>>>>is a Select-Trac NP242J) the shifting sequence goes thru 4 wheel part
>>>>>>time
>>>>>>first and sometimes would want to 'hang' in part time, requiring a bit
>>>
>>>of
>>>
>>>
>>>>>a
>>>>>
>>>>>
>>>>>>yanking motion to engage full time 4 WD.
>>>>>>
>>>>>>any more thoughts????
>>>>>>
>>>>>>thank YOU
>>>>>>paul
>>>>>>
>>>>>>
>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>news:61cxg.896$zg.578@tornado.rdc-kc.rr.com...
>>>>>>
>>>>>>
>>>>>>>Yes 3 u-joints on the front drive shaft (2 at transfer case end and 1
>>>>>>>at
>>>>>>>differential).
>>>>>>>I will try disconnecting it and see what happens.
>>>>>>>The filings are very small -- sliver like....... crossing fingers.
>>>>>>>
>>>>>>>thanks
>>>>>>>paul
>>>>>>>
>>>>>>>"Mike Romain" <romainm@sympatico.ca> wrote in message
>>>>>>>news:44C4C5F5.A18C86B@sympatico.ca...
>>>>>>>
>>>>>>>
>>>>>>>>You have 3 u-joints on the front driveshaft. I would remove that
>>>
>>>and
>>>
>>>
>>>>>>>>try driving it before I messed with the t-case.
>>>>>>>>
>>>>>>>>Metal filings aren't a good sign though....
>>>>>>>>
>>>>>>>>Mike
>>>>>>>>86/00 CJ7 Laredo, 33x9.5 BFG Muds, 'glass nose to tail in '00
>>>>>>>>88 Cherokee 235 BFG AT's
>>>>>>>>Canadian Off Road Trips Photos: Non members can still view!
>>>>>>>>Jan/06 http://www.imagestation.com/album/pi...?id=2115147590
>>>>>>>>(More Off Road album links at bottom of the view page)
>>>>>>>>
>>>>>>>>paul wrote:
>>>>>>>>
>>>>>>>>
>>>>>>>>>Double DOH and a YIKES!
>>>>>>>>>
>>>>>>>>>Drained remaining fluid (less than a quart came out) noticed some
>>>>>>>>>very
>>>>>>>>>small
>>>>>>>>>metal fines near the drain plug.
>>>>>>>>>Added fluid and went for a test drive -- low speed click is still
>>>>>>>>>noticable,
>>>>>>>>>growl is worse and vehicle is jerking when put into full time 4
>>>
>>>wheel
>>>
>>>
>>>>>>>>>drive.
>>>>>>>>>
>>>>>>>>>This is sounding serious (translate $$$$) any ideas?
>>>>>>>>>
>>>>>>>>>thanks
>>>>>>>>>paul
>>>>>>>>>
>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>news:NIQwg.4$zg.1@tornado.rdc-kc.rr.com...
>>>>>>>>>
>>>>>>>>>
>>>>>>>>>>DOH!!!!
>>>>>>>>>>transfer case was VERY low on fluid,,,, apparent leak towards
>>>>>>>>>>front.
>>>>>>>>>>Is
>>>>>>>>>>there a seal that needs to be replaced? How difficult of a job is
>>>>>
>>>>>it?
>>>>>
>>>>>
>>>>>>>>>>thanks again
>>>>>>>>>>paul
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>"paul" <SPAMpdrapeau@wi.rr.com> wrote in message
>>>>>>>>>>news:BqQwg.3$zg.0@tornado.rdc-kc.rr.com...
>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>>Wife's 95 XJ - I6, automatic transmission
>>>>>>>>>>>
>>>>>>>>>>>Previously there was a clicking at low speed and growl at higher
>>>>>>>>>>>speed,
>>>>>>>>>>>inspection showed that both front axle U-joints were bad.....
>>>>>>>>>>>replaced
>>>>>>>>>>>them this weekend (big thanks to Mike R. for the 'sacrificial
>>>>>>>>>>>bolt'
>>>>>>>>>>>trick
>>>>>>>>>>>and Bill ------ for http://www.4x4wire.com/tech/axle/ujoint/ -
>>>
>>>in
>>>
>>>
>>>>>the
>>>>>
>>>>>
>>>>>>>>>>>past I managed to break 2 vises trying to do the receiver socket
>>>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>press socket trick - I don't care what Bill does with farm
>>>>>>>>>>>animals,
>>>>>>>>>>>or
>>>>>>>>>>>his grammatical skills - he replies frequently and provides good
>>>>>>>>>>>links).
>>>>>>>>>>>
>>>>>>>>>>>Went for a test drive after changing u-joints - immediately
>>>
>>>heard
>>>
>>>
>>>>>>>>>>>a
>>>>>>>>>>>clicking noise (similar to a bad u-joint sound) - drive shaft
>>>>>
>>>>>joints
>>>>>
>>>>>
>>>>>>>>>>>showed no slop when shafts are rocked back and forth. Over 40
>>>
>>>mph
>>>
>>>
>>>>>and
>>>>>
>>>>>
>>>>>>>>>>>a
>>>>>>>>>>>growl is heard from transmission area, shifting into neutral
>>>
>>>does
>>>
>>>
>>>>>not
>>>>>
>>>>>
>>>>>>>>>>>effect the noise, shifting into 4 wheel drive increases the
>>>
>>>noise.
>>>
>>>
>>>>>>>>>>>Transmission fluid level is good and no discoloration.
>>>>>>>>>>>
>>>>>>>>>>>In 2 wheel drive if pressure is put on the transfer case shift
>>>>>
>>>>>lever,
>>>>>
>>>>>
>>>>>>>>>>>the
>>>>>>>>>>>sound varies slightly - small vibration can be felt through the
>>>>>
>>>>>shift
>>>>>
>>>>>
>>>>>>>>>>>lever.
>>>>>>>>>>>
>>>>>>>>>>>??????????
>>>>>>>>>>>
>>>>>>>>>>>thanks
>>>>>>>>>>>paul
>>>>>>>>>>>
>>>>>>>>>>
>>>>>>>>>>
>