Transfer case advice

MojaveKJ · **Posted:** Fri Jan 06, 2012 8:09 pm

I have an 04 KJ with the NP242 TC in it and for a while now, when I initially put it into 4Lo, it will not fully engage and I'll hear a grinding noise and it will slip into neutral. I've come to learn on this board that it is likely the cable linkage that is causing the problem, which I am confident I can solve myself. Before I had it out in JV last Sunday I had the TC serviced and the tech said there was a lot of metal shavings in the fluid and on the magnet plug of the TC. The issue happened again while I was in JV so I assume there are more metal particles in there now.

My questions are how damaging is it to have those metal shavings floating around in the TC fluid? Should I have the fluid changed before I go out again? Does the plug magnet catch all the particles? I am worried that because this has been happening for a while there may be serious permanent damage to the TC and maybe it needs to be rebuilt or replaced...?

What do you all think? Thanks for taking the time to read and (I hope) respond.

-Tony a.k.a MojaveKJ

ridenby · **Posted:** Fri Jan 06, 2012 8:34 pm

would change out fluid asap. When you shift,do you first put main trans in "N" then shift transfer? Oh,and complete stop?

MojaveKJ · **Posted:** Fri Jan 20, 2012 7:17 pm

Yeah, I'm going to have it changed again. Jeep just sent me an email offer for a 4x4 drive train service... both diffs, trans and Tcase for $220 so I'll probably do that after I pull the skid plates and fix the TC lever linkage. Then on to the rear control arm bushings, that noise in the left front, extend breathers...

Thanks for the advice!

dieselenthusiast · **Posted:** Sat Jan 21, 2012 7:26 pm

I had the Transgo Shift Kit installed back in early 2007. The kit is known as a “correction kit” and isn’t anything fancy. 90% of the kit can be installed in the valve body. There is one spacer plate that needs to be installed when the transmission is out. However, the directions clearly state that the spacer plate does not need to be installed to make the shift kit work, however, the additional plate is recommended for the added benefits. With the stronger (tighter) springs, the Jeep does shift tighter compared to the factory springs. Those of you who have the 42RLE probably know what I’m talking about. You can feel the delay in-between the shifts. With the “correction kit”, I do not feel the lag time in-between shifts like I did before. Shift Kits are designed to make the transmission more efficient, and by doing so, the upgrade also prolongs the life of the transmission. In many cases, the Transgo shift kits also expand the hole allowing the Torque Converter to fill up with trany fluid much quicker. The TransGo shift kit for the 42RLE does not open up the hole going into the TC like it does on my Dodge Cummins. The engineers at TransGo saw that the weakest link in the 42RLE was not the transmission, but the Torque Converter itself. TransGo teamed up with a high performance Transmission shop and decided that the 42RLE needed a better TC. According to TransGo and several of their engineers, they discovered that the 42RLE is actually a pretty good transmission with the upgraded TC. Once you upgrade the correction kit and add the aftermarket TC, then you have a pretty solid trany that should last well over 200,000 miles depending on how you drive it, how often you change the fluids, and the type of fluids you use. Heat is the toughest enemy on a transmission. I would recommend changing your Transmission fluid at least every 40,000 miles with Amsoil ATF. In my opinion, the TransGo correction kit for the 42RLE is worth the upgrade. Especially for those of you who are towing or loaded with armor, the vehicle will do better on the road and out on the trail. Adding the upgraded TC in addition to the shift kit will significantly make a difference by increasing mpg, lower transmission temperatures, increase the performance (more efficient power transfer), and prolong the life of the transmission. It seems like frivolous spending at first, but the upgrades do make the Jeep more enjoyable. For those of you who are interested, you can buy the TC and shift kit from Wayne.

Wayne at APS Precision
Mobile: (408) 205-8500
Office: (408) 374-1217

Jeepin'WNC · **Joined:** Mon Nov 15, 2010 1:48 am **Posts:** 191

Mojave KJ: Man I wish Jeep would send me an email offer for 4X4 drivetrain service. Any idea how I might get that? I did the 60,000 mile service for both diffs and the transfercase myself, and spent about that much in fluids. My local dealership wants $225 just to do a trans fluid and filter change on my KJ.

RED_KJ_666 · **Posted:** Sun Jan 22, 2012 12:46 pm

When I recently opened up my 242 case I found that the Range Selector gear was missing about the outer 1/4" of the teeth, our case had always engaged hard and disengaged hard from 4 wheel drive. I had a Grand 242 in pieces on the floor of my living room (Yes living room I love renovations makes every room the garage) and the range selector gear is identical sounds like it could be your issue to me.

dieselenthusiast · **Posted:** Sun Jan 22, 2012 1:06 pm

Mojave needs to find out where the pieces are coming from. I forget, but doesn’t the T-case and the transmission share the same fluid? If so, it's either metal coming from the T-case, TC or transmission. It sounds like RED_KJ_666 has a plausible explanation. What would cause the range selector gear get chewed up?

RED_KJ_666 · **Posted:** Sun Jan 22, 2012 2:10 pm

Putting it in and out of 4wd/changing ranges on the fly Is what I'd say happened to mine, and no the Transmission and Transfer case do not share the same fluid. As hard as I have been on mine I was surprised not to find more wrong with it, all it needed was a new chain, that gear and a bearing/seal. The transfer case is easy to work on still in the Jeep, as long as your issue is in the back end of the case as mine was.

dieselenthusiast · **Posted:** Sun Jan 22, 2012 3:21 pm

RED_KJ_666 wrote:

Putting it in and out of 4wd/changing ranges on the fly Is what I'd say happened to mine

That would make sense. I know that I sometimes have a hard time getting mine to shift (feels like binding) and other times it shifts smooth.

RED_KJ_666 wrote:

and no the Transmission and Transfer case do not share the same fluid.

Thanks for clarifying.

RED_KJ_666 wrote:

As hard as I have been on mine I was surprised not to find more wrong with it, all it needed was a new chain, that gear and a bearing/seal. The transfer case is easy to work on still in the Jeep, as long as your issue is in the back end of the case as mine was.

That's good to know.

audiboy86 · **Posted:** Sun Jan 22, 2012 3:36 pm

I would split the case and check the insides over one good time. A nice flexible flash light will help you out alot when doing so. And since your going to drain and serivce it again anyway it is a win win sistuation. Plus it is cheap insurance because there have been a few sistuations where these tranfer cases have taken the transmission with them. SO split it buy a gasket kit just in case it is still good other wise you can pick up a re-man replacement for like 350.

RED_KJ_666 · **Posted:** Sun Jan 22, 2012 8:05 pm

There's no case Gasket, you just need a tube of gasket maker.

Transfer case advice

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