Ok Time to spend a few more dollars on the 1996 XJ 4.0lt. I have a 6 inch lift, dropped the transfer case 1 inch and shimmed the diff. Vibrations are minimal but it needs the final touch, A Slip Yoke Eliminator conversion.
I believe it is a 231 transfer case and a possibility of two different types of kits. Which do you recommend and why, Do I replace the existing main shaft in the transfer case with a much heavier duty and shorter piece and a new aluminium tail housing and seal to accommodate the new fixed yoke or simply shorten the existing main shaft and tap a hole in the end of it to bolt on the new fixed yoke. And after all that who is the most reasonable supplier to supply the complete kit.
Vehicle is my daily commuter, I don't do any rock crawling, mainly beach and dirt tracks.
Bought mine from dirtbound offroad, should be coming this week. Can let you know my thoughts once I have it in my hands, someone else here bought the same kit a little while back, they would have installed it by now (unless it is sitting on a shelf in a garage like half my projects). Still need a drive shaft. Bought it because it's a yoke style, not a flange style.
I thought all Oz 4.0l XJ's are fitted with 242 transfer case. What year models came with 231s? I thought hack & tap was the only option for the XJ. I assume that if you've got Full-time 4WD, as well as part-time & low range, you've got a 242, correct?
A bit of web searching and I found my possible answer
There are several different configurations for a NP231 transfer case, but only one or two for the NP207 and NP242. These options are both offered from Rubicon Express in the form of their Hack and Tap SYE. It requires you to cut the rear output shaft down to 1" and tap the end so that a flange can be slid over the splines and bolted to the output shaft. The 96+ H-n-T kits for the NP242 are much cheaper than the older style ones. The reason behind this is that the older units have a flange and a housing that must be fitted. The 96+ are sealed housings, so it only requires the flange.
Pity as the replacment housing and shaft assembly appears to be more heavyduty..
Well hack and tap I go
Iv run the RE Hack & Tap SYE's on all my XJ's with a double carden shaft & i have never had a drama with them , fit & forget about it mate my 01 xj has the 242 transfer & the only difference between it & my 94 sye is the 242 retains the original output seal & the 94 came with a new housing
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SYE Kit Which one ??
, Yes after looking at the t/fer box it is a NP242. So a hack and tap may be the one only option..
