NP242J Rebuild HELP tracking down small parts! Going Grey In A Hurry... haha

[JeeperWill]

Hey guys,

So at 280k and about 20 years of service I've decided it's time to rebuild my np242 transfer case. I ordered up a new Crown chain and a G2 rebuild kit. Should be here in about a week.
I've never rebuilt a np242 but have a fair bit of mechanical expertise. So versus just dismantling and reassembling the case with new parts which I'm sure I could manage blind... Does anyone know of a thread or link to a rebuild guide or write up that I could reference in case I have any issues? or any tips, tricks, and or words of wisdom you want to pass on?

Thanks guys.

[hps4evr]

There must be something out there in Google land that has a blown up diagram or step by step procedure. But we did one a while ago and it wasn't much more difficult then going through a 231. I don't think you'll have any problems.

[JeeperWill]

Cheers Eric! I did find a couple of exploded views. I think I'll just disassemble it on the bench carefully in order then reverse with new goods. I feel better hearing that from you. haha

I know the np231 is simple but had my reserves about the np242 for a first go.

[CatSplat]

There's some guides floating around for swapping the input shaft which requires a complete teardown, one of those should get you going. Really the only tricky part is dealing with removing the rollpin on the shift rod via the access hole in the front half of the case.

[JeeperWill]

Okay, so I have the G2 seals and bearings overhaul kit and a crown chain. This is my first transfer case rebuild and all is going well except I am having difficulties with why the kits only come with half of what you need and now trying to track stuff down its looking like I could be walking for 1-4 weeks just waiting on stupid little parts...
I need an oil slinger for the front output shaft as mine was damaged upon removal and is no longer trust worthy for surface mating with the seal. Next I need the smaller lock rings. I don't believe those are reusable... they are also now stretched wide open from removal... help please? I've called all over town and the soonest I can find on even the oil slinger is a week and I'm totally lost on tracking down the correct lock rings.
So to recap, the rebuild is going smooth... except for stupid little parts that should be included in the rebuild kit and of course are not. WTF!? Right!?

[JeeperWill]

Mopar #J8134488 for anyone else facing a similar issue here is the lock ring part number that you need that does not come in any kits that I've seen. My source was Jeepforum.com and confirmed with Tower Chrysler. They are discontinued technically but have access to over 1500 of the little buggers. Now it is just the waiting game for those and my oil slinger that mounts on the front output shaft between the yoke and seal. Slinger # 5016615AA (crown automotive)

I hope this helps anyone else attempting this same overhaul... as I was going grey trying to track this all down. Haha, sigh of relief.