NP 242 Hack n Tap install


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Old 04-20-2014, 06:03 PM   #1
Gluckmysock
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Default NP 242 Hack n Tap install

Greetings! This is a write up of the procedure to install a Hack n Tap Slip Yoke Eliminator (SYE) on an NP242 Transfer case.

The patient is a 1996 XJ Cherokee with a 4.0 engine, AW4 transmission and an NP 242 Transfer case. I put a 3" lift on it and have a 3 degree pinion shim on the rear.
I used this link as a guide: HowtoSYEconversion Lots of good info in there.

Materials needed are as follows:

1. 3103-27CV SYE (IRO sells a nice kit IR-XHNT)
2. Front drive shaft (to replace rear, must be from an Auto trans cherokee)
3. Drill bits (3/16, 21/64)
4. Thread Tap (3/8"-24, fine thread)
5. Cut off wheels, several thin ones.
6. PB Blaster, (cutting lubricant)
7. Brake/parts cleaner, (clean parts and threads)
8. 242 Thread Locker (blue)
9. Tape
10. If you don't get a complete SYE from IRO, you will also need the following hardware; (4) 5/16"-24 x 1.5" Grade 8 bolts with flat washers. (1) 3/8"-24 x 1" Grade 8 bolt.
11. New rear yoke cap bolts, (I think they are 1/4"-28)

Once again this is the link I used as a guide (Howto SYE conversion) so I am posting the actual "Hacking" part.

CHOCK THE FRIGGEN WHEELS!! I didn't include a pick but if you do not know how then maybe this isn't for you. Once you remove the drive shaft, the vehicle is in neutral and will drift and run over you!!

Remove the drive shaft and clean the output shaft (or the tape won't stick) so it can be marked at 1-1/4" of splines:

After the shaft is marked, wrap it with tap (I used foil tape so it didn't melt from the heat):


Start the engine and put the trans in reverse and start cutting at the tape, here is a pic of the shaft partially cut:


Cut complete, took about 2 minutes to whack it off:


Starting the 3/16" Pilot hole:


Drilled the 21/64" hole:


Tapping (threading the hole) with a 3/8"-24 tap:


Tap removed to clean threads. I used a rag to clean the shavings out of the flutes on the tap, I did this about every 1/4" to 3/8":


The hole was drilled 1 and 1/4" deep. My tap only had threads 1 and 1/4 " deep so now I know the hole is completely tapped:


I ordered my 3103-27CV yoke from Northern Drivetrain:


Its a little too long and needed the 3/8" hole drilled in the center:


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ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month

Last edited by Gluckmysock; 04-20-2014 at 06:17 PM.
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Old 04-20-2014, 06:03 PM   #2
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Marked and scoring it 2 and 1/2" shorter. I used a 3" bolt to secure it to the shaft and had it spinning while cutting. WARNING, if you cut too deep you may score your splines. I removed it and put it into a vice to CAREFULLY finish cutting. I also used a flap wheel in a die grinder to chamfer and clean up the insides of the splines:


SYE Installed, YEAH!! I put anti-seize on the splines and used 242 Thread locker on the 1" x 3/8"-24 bolt threads and tightened accordingly:


Here is the angle with the new drive shaft installed:


And the angle of the pinion, checked from the cover bolts, that's why they are about 88 degrees difference. Which put me within the 2-3 degrees needed:
.

And there you have it! Took me about 4 hours, including removing rear drive shaft and installing new one. Just take your time and double check all your measurements.
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ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month

Last edited by Gluckmysock; 04-20-2014 at 06:12 PM.
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Old 04-20-2014, 06:27 PM   #3
wtfjackbbq
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It's the little things that I never seem to think of. I never thought to put my transmission in reverse for an even cut. Mine was pretty crooked and then I grinded it flat. It took way longer lol. It looks good.
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Old 04-20-2014, 06:32 PM   #4
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Thanks!
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ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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Old 04-26-2014, 12:19 PM   #5
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Just wanted to throw up some more pics. The Slip yoke on the used drive shaft was SHOT! I had it rebuilt and a new u-joint installed. As you can tell by the pics, I only have maybe 1" of slip in the new yoke, Hopefully, that's enough:





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ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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Old 05-07-2014, 05:53 AM   #6
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UPDATE: This shaft was from the front of an 01 XJ and only $20.00 from a fellow on craigslist. Do yourself a HUGE favor. If you get a used one, HAVE it checked and balanced at a drive line shop.

This one has been a royal PITA. Everything seemed tight when I bought it, After cleaning, I found it full of dirt, once cleaned, the slip yoke was worn and had to be replaced. With the slip yoke assembly, rear yoke and u-joint, I'm out $120. But it's piece of mind, ok. Major Vibs after the install, I return it to the drive line shop and have it rebalanced and and the shaft tube shortened 1", Reinstall and I get major vibs from the shaft, and I have already installed 4* pinion shims. Checked the CV u-joints (double cardan side) and has a ton of movement. Appearently I have loosen up all the dirt from the few days of driving. Replaced both u-joints and the center pivot, Another $85.00.
I'm over $220.00 on a used freaking DS. Now I still have a vibration at 55-65 mph. DANG!

Read somewhere to use hose clamps around the DS to check balance, so I picked up 4 hose clamps and after jacking it up, pulling the rear wheels, and using lug nuts to hold the drums on. started it up and put it in drive. will the rear DS spinning, I VERY CAREFULLY, slowly placed a paint marker near the front of the DS and rear, High spots, or Out of balance spots would barely touch the marker, leaving a line of paint in the area. Using the hose clamps as a weight, I attached it with the screw on the opposite side of the paint mark, After 3 clamps, the Vibs were gone. I had to put it all back together and take it for a test ride, But I am confident, when I get it balanced at the drive line shop, again, my vibs will be gone and this problem will be over.

Wish me luck!
__________________
ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month

Last edited by Gluckmysock; 05-07-2014 at 05:59 AM.
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Old 05-07-2014, 04:53 PM   #7
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I'll just leave this here for someone about to do this and is considering cost... $270

http://www.4xshaft.com/
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Old 05-07-2014, 05:29 PM   #8
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Quote:
Originally Posted by wtfjackbbq View Post
I'll just leave this here for someone about to do this and is considering cost... $270

http://www.4xshaft.com/
You cut me Bro! ya cut me deep.

Nah!! JK.

__________________
ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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Old 05-07-2014, 07:05 PM   #9
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I'm getting set to do this on Friday. I c u left 1 1/4 " of spline is that the min. Also. I saw you had the slip shortened how much and was it bottoming out. Sorry I didn't loo at the link you posted yet I'd rather first hand and then I'll see what they have to say
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Old 05-07-2014, 07:39 PM   #10
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1 1/4" of splines is what I left. Pretty much all the forums I checked listed it the same. That's really all you want sticking out or you just put more weight on the output shaft. Also, it's to accommodate the front drive shaft length, which, BTW, was actually made LONGER by the drive line shop when I had the rear slip yoke and splines replaced. They have since shortened it by an inch and it looks to have about 1 1/2" of slip.
__________________
ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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Old 05-07-2014, 07:48 PM   #11
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The instructions on the IRO hack-n-tap said no smaller than 1.25"
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Old 05-07-2014, 07:51 PM   #12
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Quote:
Originally Posted by wtfjackbbq View Post
The instructions on the IRO hack-n-tap said no smaller than 1.25"
isn't that the same as 1 1/4"??
__________________
ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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Old 05-07-2014, 08:17 PM   #13
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yea it's easier to hit the"." for some reason. Enough so that I actually paused and though of which way I was going to type it...
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Old 05-15-2014, 09:19 PM   #14
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Can you hack and tap a 231
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Old 05-15-2014, 09:25 PM   #15
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Quote:
Originally Posted by dkd0312 View Post
Can you hack and tap a 231
In a word, YES! Here is the write-up I followed: How To SYE Conversion


__________________
ZBeard: "How do you make good decisions? Good judgement. How do you get good judgement? Experience. How do you get experience? Bad decisions".

1996 Cherokee classic. 100k Miles, I6 HO, AW4, Np242, D30/C8.25 3.5" RE lift
My build thread: Gemini
NP242 Hack n Tap (SYE) Install
Common links: Budget MODS List And All You Ever Wanted to Know About an XJ

December 2013 Stock Class Cherokee of the month
May 2015 Modified Cherokee XJ of the Month
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