231 J Transfer Case Swap

[xTHExFISTx]

my 94' XJ just started to clunk real bad.at first thought it was the U-joints,but i jacked the rear end up on jack stands,and when it goes into reverse or drive it starts the clunking,at high speeds it sounds like popcorn.The sound is coming from the transfer case.It has a rebuilt 231J in it (not professionally done).my question is should i rebuild or swap for a 242J which i can get really cheap.Thanks,and sorry so long.

[xTHExFISTx]

when looking in the drain plug for the t-case it was completely empty and the chain was really loose.Could that be what was making the noise?I plan on taking out this weekend and taking apart.if is just the chain,do i have to take everything apart,and what else should i replace while in there.I dont plan on using the jeep off road so i dont care much about torque and things,i just want it to run.

[MagicRat]

Well, a 242 case is a different animal, and has its own reliability issues regarding the limited slip clutch inside. Personally, I do not think its an improvement, and I would not buy any used 242 case unless I saw it in operation or it came from a reputable parts supplier, with a returns policy.

If you were driving for any length of time with little or no fluid, your case is likely scrap inside. The case uses hundreds of tiny roller bearings which will fail (or become badly worn) very quickly is run with no fluid.

BTW in 2 wheel drive, the chain does not turn when the rear wheels are in the air, so any looseness there would not produce noise in 2wd.

I know this is not what you want to hear, but I think you need another 231 case.

[xTHExFISTx]

damn,the 242 comes from a 92 jeep XJ my father in law has.Ive heard you just have to change out to the new drive shaft.He will sell the whole jeep to me for $250.is there any way to run without t-case if i plan on not using 4 wheel drive?Thanks MagicRat.