The New Process / New Venture 242 transfer case has turned out to be one of the greats in Jeep history, as well as other applications such as the Humvee. Having rebuilt countless 242's and as a manufacturer of parts for them, no company knows them like Novak.

Master Rebuild Kits

Kit Features

Our master rebuild kit has been assembled for our customer's rebuilds as well as our own. It is hands-down the most complete kit we've seen anywhere and features all the usual consumable and wear item components seen in standard kits, including world class bearings, premium seals, gaskets, small parts, shift lever bushing, etc. (not all items shown in image).

Most cut rate kits on the market are missing the following parts included in every Novak rebuild kit:

• Case magnet
• Output shaft accordion boot & clamp
• Shift rail bushing
• Oil slinger
• Output housing bushing
• Oil filter
• RTV silicone
• Loctite
• 12 planetary thrust washers, bronze, upgraded from plastic
• Face mounting studs
• Novak's instruction guide based on the years worth of rebuilds of these transfer cases that we've done

A chain is not included in our 242 master kit, but is strongly recommended that you replace. Please read about Chains, below and select the correct one in Related Products, below. These are the highest grade chains available.

NP242 Versions

NP242's input bearing widths 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 NP242 and check this input gear bearing.

• The early NP242 uses a BD50-8 bearing, measuring 24mm wide
• The later NP242 uses a 6010-N bearing, measuring 16mm wide

The earlier style input gear, left, has a wide bearing journal. The later style input gear, right, has a narrow bearing journal.

For a more in-depth discussion of these versions, see this page.

NP242 Transfer Case Chains

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)

These can be purchased in Related Products, below.

Related Products