Installing Novak Cable Shifter On A Np242

[Blue88Comanche]

Instilling the Novak Cable shifter on an AX-15/NP242 combo
 
I was in need of a new transfer case linkage setup after I replaced my BA-10/5 & NP231 with an AX-15 & NP242. I purchased the Novak Cable Shifter Kit for$195.85 shipped from Novak-Adapt.com.  If you don't want to spend nearly $200 on a cable shifter, then take a look at THIS DIY Linkage, I rediscovered it after I ordered my Novak kit.  Before I installed my kit I read over Flint54's install thread.  I did not do all the modifications he did, such as to the shift gate.  I don't know if Novak changed the kit between the time Flint54's installed his kit and I bought mine.  The install took about 2 hours.  A second person may be needed during the install.  I did not need to remove the cross member or lower the transmission to install this kit, however it would have made things simpler.  This kit is not exactly "bolt on" if you have a NP242 like me, some modification may be required.  If you had Rhino liner sprayed in the cab you may soon regret it as I did.
 
Keep in mind this is for General Instruction.  This is how I did the install.  This install was on a 1988 Jeep Comanche, 4.0 I6, AX-15, NP242.  Also note my MJ does not have all the factory sized bolts as some have been replaced over the years, I may give a bolt size that is different from factory.
 
Tools Required:

• Saftey Glasses
• Gloves
• Box Cutter (If you have Bed liner in the cab)
• Wrenches (8mm, 10mm, 13mm, 15mm, 17mm, 1/4, 1/2, 9/16, 15/16, these are what I used)
• Allen wrenchs
• Drill
• Needle nosed plyers
• Floor Jack (if you decide to remove the crossmember)

Start by blocking off the tires and setting the parking break.  The Jeep may need to be shifted into neutral during the install.
 
Here are the parts in the Kit: Body side bracket, Transmission bracket, Shifter cable, and a bag containing 4 Allen head bolts, transfer case lever, ball joint of some type, and a clevis yoke.

 
If you haven't already remove the front drive shaft.  Use 8mm Socket or wrench to remove the bolts on the front diff yoke and 1/2 wrench for the transfer case yoke bolts.
 
Removed was the body side linkage bracket.  It is located on the driver's side of the transmission tunnel.

 
I had the joy of removing bed liner from the bolts holding the body side bracket on.

 
Its a PITA getting that stuff off.

 
Use a 10mm wrench or socket to remove the bolts.  After all the bolts are removed the bracket should fall off.

 

 
I had to use a wrench to pry the linkage bracket from the shifter bushing. I then used a knife to remove the Bushing it self.

 
Installing the new Novak body bracket did not go on as smoothly as I would have liked.  I also needed a second person to put the bolts on while I held the bracket in place.  Use an Allen Wrench (sorry not sure what size) to install the body mount.  Not all the holes lined up properly, but it did not take much to fix the problem.

 
Next I moved on to the Transfer case lever.  Use a 9/16 wrench to remove it.  

 
There are some Differences between the stock lever and the Novak lever.

 

 
As in Flint54's thread I later discovered I needed to add a new hole to the Novak lever.  I used a drill bit the same size as the hole...  Sorry I don't know what size it is.  Before you copy my placement please read THIS thread by Flint54.  But After I had everything together I guessed where it needed to be based on the placement of the clevis yoke...  The new hole placement between My TC lever and Flint54's lever seem to be about the same.

 
Reinstall the Transfer case lever using the 9/16 wrench or socket.

 
These two bolts will need to be removed with a 9/16 wrench.  (I did not have any of the AX-15 linkage brackets.)

 
Place the bracket on the Transfer case studs and replace the bolts.

 
I attached the Cable as instructed in Flint54's install thread.  Note: My cable did not line up directly to the Handle lever and Transfer case lever.
Both cables are adjusted by two 15/16 nuts.  Like in Flint54's Install both cables are installed as to where the aft bolt just has full thread engagement.
 
This picture shows the Transmission mount adjustment.

 
This picture shows the body mount adjustment.

 
Here are how the two ends attach to the handle and transfer case levers.
 
Handle Lever

 
Transfer case Lever

 
Reattach front drive shaft...
 
Now everything should be hooked up.  Thus far the biggest difference between My install and Flint54's is the shift gate.  I currently have the 231 gate on the truck, I have a 242 gate somewhere I just need to locate it.. 

Edited November 25, 2015 by Blue88Comanche

[AeroNautical]

Awesome write up. I'll be doing this soon, but on a 231, so probably a bit less hacking and drilling for my install. Thanks

[Blue88Comanche]

Thanks!  The 231 should go smoother.  I think the modifications are for the longer throw in the 242.

[Jeep Driver]

What is the benefit to installing  the cable?

[Blue88Comanche]

For me it was getting the 4wd shifter working again. As I did not have any of the AX-15 linkage.

 

It provides smoother shifting, and should be less likely to kick the TC out of gear.

[Alexia]

YES! This single thread has restored half my sanity trying to install this shifter. All I need to do now is the drilling the transfer case lever so that the shifter throw is not this ridiculous new length now.

[Blue XJ]

Nice write up.   I just installed one for my 231 with an AX-15.  I had to modify the bracket to get it to attach to the AX-15, there wasn't enough clearance to fit over some casting on the trans. 

[AeroNautical]

Nice write up.   I just installed one for my 231 with an AX-15.  I had to modify the bracket to get it to attach to the AX-15, there wasn't enough clearance to fit over some casting on the trans.

 

I had that exact problem, too. Nothing a minute at the grinding wheel didn't fix, though.

[Blue88Comanche]

I am glad this write up was helpful. where there any more pictures that may need to be added?

[88AKChief]

 

After messing around with it more during the day i noticed while shifting the handle into 2wd I was bumping the console (circled in red).  I may end up trimming the shift gate like Flint54 did during his install at the areas circled in yellow.

 

 

I know this is a year late and therefore may be a moot point. but with the Novak cable you should be able to "shorten" the cable using the jamnuts at the cable ends, which would also shorten the throw and from your pictures it appears that there might be enough adjustment at one or both ends of the cable end jamnuts to back it off the front of the shift gate. anyways just food for thought, i like this write-up its very informative. pictures are a plus.

[Blue88Comanche]

 

 

 

After messing around with it more during the day i noticed while shifting the handle into 2wd I was bumping the console (circled in red).  I may end up trimming the shift gate like Flint54 did during his install at the areas circled in yellow.

 

 

 

I know this is a year late and therefore may be a moot point. but with the Novak cable you should be able to "shorten" the cable using the jamnuts at the cable ends, which would also shorten the throw and from your pictures it appears that there might be enough adjustment at one or both ends of the cable end jamnuts to back it off the front of the shift gate. anyways just food for thought, i like this write-up its very informative. pictures are a plus.

 

 

I haven't messed with it any after i did the install.  But from the pictures it does look like i could back out the adjustment on the body bracket.

[Blue88Comanche]

Picture links are dead, I will get them fixed here in a bit when i have some time.

[Blue88Comanche]

All pictures have been restored.