flint54 Posted November 21, 2012 Share Posted November 21, 2012 After a lengthy, meticulous, and costly surgery, it now appears I just might have to go in again, but I surely hope not! Here's the deal. I converted from 231 to 242, and my 242 needed an input gear swap to 23 spline. So, I did a full-up rebuild, all bearings, bushings, pads, seals, chain, the works. I followed the FSM each and every step and image and double checked everything. Bench checkout seemed to confirm perfection. Now it's back in the vehicle, along with a Novak cable shifter (adjusted per their tech sheet), and the correct 242 shift gate. With the shifter full forward, I get 2wd. Next notch I get part time 4wd. Next notch I get full time 4wd. Offset and next notch I get neutral. Pull shifter to full back of gate and I get........neutral. I cannot get 4wd low. I even pulled the gate off to make sure that wasn't the problem. Per Novak, some shifter handles were delivered with wrong angle, they sent me a template for correct angle and mine was perfect. I'm not in dire need of 4wd low, but after all that time and cost and effort, dammit, I want it to work correctly. I've tried to shift while, and after, rocking the truck back and forth to minimize engagement issues, but no dice. Any 242 surgeons care to advise me? (yes, it has correct fluid) Thanks! Link to comment Share on other sites More sharing options...
mvusse Posted November 21, 2012 Share Posted November 21, 2012 Even with a 242 shift gate I hat trouble adjusting Sparkles linkage to go all the way from 2wd to 4-low. Best I could get was so close to 4-low you could hear the gears grinding but no engaging. Ended up taking a Dremel to the shift gate and elongating the slot 1/4" in the back. Works flawlessly now. Link to comment Share on other sites More sharing options...
reece146 Posted November 21, 2012 Share Posted November 21, 2012 Sounds like an issue with the shifter. These cases are pretty simple... if you got it put togehter without spare parts it is likely correct. Get under the Jeep and disconnecct the shifter. Run the transfer case through it's settings without the shifter to ensure you can get every postition. Link to comment Share on other sites More sharing options...
knever3 Posted November 21, 2012 Share Posted November 21, 2012 I have the same problem after rebuilding my 242 and my Novak cable will not make it to 4low. Either I have 4low or 2wd high, not both. I told Novak that their cable needed to be longer to make all the movement. I still need to revisit mine. Let us know how you make out! Link to comment Share on other sites More sharing options...
flint54 Posted November 24, 2012 Author Share Posted November 24, 2012 Success! Had to make a few modifications, but it works as it should now. Here's the writeup: http://comancheclub.com/topic/36155-novak-shift-cable-on-np-242/ in the DIY section. Link to comment Share on other sites More sharing options...
Thunderbear Posted November 24, 2012 Share Posted November 24, 2012 Success! Had to make a few modifications, but it works as it should now. Here's the writeup: http://comancheclub....able-on-np-242/ in the DIY section. Wow. Nice work. How does the 242 like the manual trans? Read more than a few people posting that didn't recommend it behind a manual. Link to comment Share on other sites More sharing options...
flint54 Posted November 25, 2012 Author Share Posted November 25, 2012 Interesting. I wonder what the objection might be? I doubt it is a design or a performance issue, otherwise 4wd and manual trans would not be offered together and I've seen a great many of them paired. Perhaps they don't line manual trans? There are surely times when I wish my truck was an auto, in fact the thought of converting creeps into my head from time to time. I just cannot see how the T case and the manual trans coud be detgrimental to each other, or how the trans would even have a clue whether it was being chased by a 231 or a 242, or any other device. Anyone here wish to offer any concerns or observations? Link to comment Share on other sites More sharing options...
A-man930 Posted December 4, 2012 Share Posted December 4, 2012 I still catch myself considering a 242 for that Full Time option. Too bad there isn't a low range kit for it :( Link to comment Share on other sites More sharing options...
mvusse Posted December 4, 2012 Share Posted December 4, 2012 And what do you do that needs deeper than 2.72:1? You could always put a range box in front of it. Link to comment Share on other sites More sharing options...
A-man930 Posted December 4, 2012 Share Posted December 4, 2012 Not really a NEED as much as a want. I'd like to keep my sissy 3.54 gears when I upgrade to 35" tires and want to cruise to work and back while still having actual LOW range available. A 4:1 kit in a 231 fits that bill quite nicely. A doubler is a thought though... idk Link to comment Share on other sites More sharing options...
Thunderbear Posted December 7, 2012 Share Posted December 7, 2012 Interesting. I wonder what the objection might be? I doubt it is a design or a performance issue, otherwise 4wd and manual trans would not be offered together and I've seen a great many of them paired. Perhaps they don't line manual trans? There are surely times when I wish my truck was an auto, in fact the thought of converting creeps into my head from time to time. I just cannot see how the T case and the manual trans coud be detgrimental to each other, or how the trans would even have a clue whether it was being chased by a 231 or a 242, or any other device. Anyone here wish to offer any concerns or observations? Most often posted is the possibility of "input shock" from the manual trans which is negated by the slushbox. Seems to me like not shifting like a retard would make it a moot point. I love the 242, and would have one in my other truck if I could. Link to comment Share on other sites More sharing options...
flint54 Posted December 7, 2012 Author Share Posted December 7, 2012 RE: " Seems to me like not shifting like a retard would make it a moot point." Yep! If somone is going to firewall the throttle and dump the clutch, they should just expect bad things to happen occasionally. Link to comment Share on other sites More sharing options...
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