The New Process / New Venture 242 transfer case is one of the most durable and rebuildable transfer cases in the history of Jeeps.
For Early NP242 Versions
For Late NP242 Versions
For Liberty NP242 Versions
Our master rebuild kit has been assembled for our customer's rebuilds as well as our own. It is the most complete kit we've seen anywhere and features the recommended consumable and wear item components.
Because there are a few chain options for the NP242, we recommend it be purchased (below) for the most complete rebuild possible. We consider chain replacement to be very important.
All kits include all the bearings, seals, gaskets, small parts, and instruction guide.
NP231's are consistent from 1988-1993. Beginning in the 1994 model year, New Venture changed the front input bearing from a wide version to a narrow version. By 1995, the change-over was complete, but individuals with 1994 model year transfer cases can't always be certain of which bearing their transfer case may actually have, unless they pull the front bearing retainer or even fully disassemble the NP231 and check this input gear bearing.
The earlier style input gear, left, has a wide bearing journal. The later style input gear, bottom, has a narrow bearing journal.
For a more in-depth discussion of these versions, see this page.
There were five chain versions available in the NP / NVG 242 transfer cases. They generally fall into the applications as listed below. However, if you are at all uncertain about your 242, you can open it up and inspect the pitch of your chain (by measuring between links) and the link type as illustrated below:
Use the above illustration in the event you may not be certain about the provenance of your NP242 transfer case and the chain type it features.
Jeep XJ (US) & ZJ Version, 1989-2000 (most common in Jeeps unless it has a V8)
Jeep WJ & Dodge V8 Version
Jeep Liberty 2002-present
Jeep XJ & ZJ (Europe), NP242ECE
The #HV061 transfer case chain for the NP242ECE, Jeep (European) XJ & ZJ, features an 0.5033" pitch rocker joint x 1" wide x 72 links. This chain is, unfortunately, no longer available.
HMMWV Humvee Hummer H1 Version
Essentially all parts for the 242 are available new and affordably so. For anything not shown, contact us.
It is very common for our customers to do top-level rebuild work, using good methods and by following our included instruction guide. We suggest the rebuilder have access to a set of snap ring pliers, and a small arbor press, in addition to standard shop tools.