Hello, all KJ Owners:

Does anyone know if there is an aftermarket upgrade kit for the NV242 transfer case that was common in the Liberty CRD?

I will be upgrading the engine soon, and I want to make sure the driveline can handle the power. I know kits are available for the 545RFE 5-speed automatic transmission, and that will be done also. I am simply worried about that aluminum cased transfer case... the thing looks flimsy to me.

most people just blow the front differential - that's why Al sells a Steel replacement.

I think JJ had mentioned someone blowing up a 242 - but it's sure not as common.

at one time some shops that sell parts for the 231/241 - had said that the upgrades fit a 242 - but they were talking about slip-yoke eliminators - not gear upgrades.

for gears - the 242 came in 3 variants - the Liberty version, a Durango one and an original Hummer version

not sure if any parts/pieces interchange - you might be able to find a Durango transfer case and measure it.

folks looking to change - tend go to the 231/241 - significant strength increase - but you lose Full-time 4x4.

(at one time I found a website - with numbers - but then NewVenture sold the business and the links died)

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

Thank you for the reply, ATXKJ!

I would be interested in simply making the NV242 stronger, and to avoid doing anything else like changing gear ratios or going with a different transfer case and doing without the Full Time 4x4. My Wife and Mother drive these vehicles and find the Full-Time 4x4 very handy on our slippery roads and highways in the winter.

I am hearing a slight clunking sound coming from under the CRD right about where the transfer case is when I move from a dead stop, or move after shifting from forward to reverse, or reverse to forward. It is not loud at this point, but I do not want whatever is causing that noise to crater before I have had a chance to upgrade it.

Have you check ujoints? greased slip yoke? checked upper control arm ball joint?

all of those are very common problems, not the Transfer case.

as note Google found a NV spec chart -linky

and the NV242 HD lists as 2x the oil capacity - so I'm guessing it's larger and would take special mounting

but I'd check the normal clunk stuff - before worrying about the transfer case

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2005 CRD
stuff
Skeptic quod gratis asseritur, gratis negatur

I will be checking everything out before rushing out to purchase anything... and you are definitely correct... those items you mentioned can all cause that problem. The information on the NV242 HD is very interesting... I would like to know more about it. I hope it still has the Full-Time 4x4 function. Thank you, ATXKJ!

novaks knowledge base covers the differences between them there's some chain differences, bearing journal differences but if I remember right it's a HD because if heat capacity not torque capacity

I'm not really aware of any 242 failures that wouldn't have likely been failures as a 231 within reason. very easy transfer case to rebuild too, used one for a learning lesson tool for a high school auto shop class

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03 Renegade (Black)
177k miles 3.7L gas - 45RFE
Command Trac / 4.10s
Lift: ft. 790+ rr. JBA4+
The last of the TrailReady Front&Rear Bumpers and TR Rock Rails
Jarhead Offroad light covers
31x10.5R15 RedLetter Grabbers on Blackrock Dunes
L.O.S.T #KD098632

Hey Jeff, sure sounds like the motor and or trans mounts as I have that same clunk in two of my CRDs.

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05 CRD: H.D.S2 stat,WW Ironrock trilink&LCA's, OX rear,ARB front, 4.10's, ARB bumper, Suncoast,OME 3.5, JBA UCA,rock rails, Moabs&265/75 Duratracs, GDE tunes ,FFD fan,ARP's, 2 micron fuel, new valves,sasquatch battery tray & grid heater, tensioner relocated
Mech fan, VH & AC delete

[/quote]Hey Jeff, sure sounds like the motor and or trans mounts as I have that same clunk in two of my CRDs.[/quote]

I have been driving around with this noise for some time now, and I am certain that the problem lies somewhere in the suspension. The "clunk" I keep hearing only occurs after a half-second delay from reversing directions, (going forwards to backwards, or going backwards to forwards).

Hey Jeff, sure sounds like the motor and or trans mounts as I have that same clunk in two of my CRDs.[/quote]

I have been driving around with this noise for some time now, and I am certain that the problem lies somewhere in the suspension. The "clunk" I keep hearing only occurs after a half-second delay from reversing directions, (going forwards to backwards, or going backwards to forwards).[/quote]

Hmm, you might check the mounts just in case. If you can start out with almost no acceleration, you might be able to delay the clunk until you're moving forward (all gears are engaged) and then you step down on it a little bit, and clunk, the motor shifts. I think Papaindigo had a good write up on how to watch the engine shift around while putting it in drive and reverse to check the mounts. I think he mentioned something about the trans mount also, which sounds closer to where you are hearing it. The mounts last only about 50k

If it is gears, there should be silver in the fluid when it's churned up.

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05 CRD: H.D.S2 stat,WW Ironrock trilink&LCA's, OX rear,ARB front, 4.10's, ARB bumper, Suncoast,OME 3.5, JBA UCA,rock rails, Moabs&265/75 Duratracs, GDE tunes ,FFD fan,ARP's, 2 micron fuel, new valves,sasquatch battery tray & grid heater, tensioner relocated
Mech fan, VH & AC delete