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  1. #1
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    Default Tom Woods NP242 SYE

    Many of you know that I have another stretched chain. Of course I won't know this for sure until I pull it a part but it fits all the past symptoms. It's the only problem I have ever had with this t-case.

    Well I guess I can't say the only problem. Apparently the other problem I have with it is my inability to repair it correctly! I'm not putting factory chains back in but then again I'm not using ultra cheap chains either. I believe the two I have put in were TRW chains, about 110 each.

    So this time I'm changing out the drive gear and driven gear, along with the chain.

    I contacted Mark (PayLess 4x) one of our vendors and ordered the goodies for the transfer case repair Friday.

    I've needed to do the SYE for years now, although I know some don't run a SYE and do just fine I'm going to go ahead and put one in. I was looking at a hack and tap for a while, but decided I'd go with my first choice, Tom Woods.

    Doing this at the same time of replacing the gears and chain makes much more sense than cracking the case more than once. It's actually pretty easy if the snap rings would actually come off on the first attempt!

    They want two measurements when you order.



    They list two choices, 3 5/8" or 3 7/32" I'd say mine is closer to the 3 7/32"



    Then I had to measure the drive shaft length...



    I came up with 35 3/8" for my drive shaft length.

    Identify the transfer case...











    So I think I have all the info I need to order my SYE and driveshaft from Tom Woods...

  2. #2
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    Default Re: Tom Woods NP242 SYE

    Tony

    The reason your chain stretched was that you did not replace the sprockets (drive gears) with the new chain. Now that you are doing that, the chain will last.
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
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  3. #3
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    Default Re: Tom Woods NP242 SYE

    Quote Originally Posted by 4.3LXJ View Post
    Tony

    The reason your chain stretched was that you did not replace the sprockets (drive gears) with the new chain. Now that you are doing that, the chain will last.
    That's what I was thinking MUST be it. I had a very minor leak which over time would make it pretty low. I think I finally resolved that issue. I think/hope it was a combination of the two.

  4. #4
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    Default Re: Tom Woods NP242 SYE

    Quote Originally Posted by Mudderoy View Post
    That's what I was thinking MUST be it. I had a very minor leak which over time would make it pretty low. I think I finally resolved that issue. I think/hope it was a combination of the two.
    When the chain stretches, it wears the sprocket out and the larger areas in between the teeth cause the chain to conform to them.
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  5. #5
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    Default Re: Tom Woods NP242 SYE

    Ordered. I ordered the drive shaft with the long spline.

  6. #6
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    Default Re: Tom Woods NP242 SYE

    Is there more lift in your future?
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  7. #7
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    Default Re: Tom Woods NP242 SYE

    Quote Originally Posted by 4.3LXJ View Post
    Is there more lift in your future?
    6.5" is all I have planned. I'll raise the rear up 1" after the SYE, then I'll see if it sits level or ass high. I'll have 4.5" front and 6.5" back at that point.

  8. #8
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    Default Re: Tom Woods NP242 SYE

    Well ordered the goodies yesterday, and received the invoice (via e-mail) today. I think that means it's been shipped!!!! I should have pictures soon.


  9. #9
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    Default Re: Tom Woods NP242 SYE

    The Tom Woods package arrived today, and Houston (or Katy) I think we have a problem...







    I need a hole!

    On the bright side I get to experience that wonderful Tom Woods Driveshafts customer support I have heard so much about!

  10. #10
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    Default Re: Tom Woods NP242 SYE

    They are good, they will make it right
    230 hp 4.3L Chevy
    Built 4L60E with manual lockout
    Atlas 4 speed
    Griffin radiator
    On board air
    Warn 9.5ti on custom bumper
    7.5" RE front and bastard pack rear on custom long arms
    30 gal gas tank
    lockers
    And a bunch of other stuff

  11. #11
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    Default Re: Tom Woods NP242 SYE

    Quote Originally Posted by 4.3LXJ View Post
    They are good, they will make it right
    Yep I bet so. Funny thing is I think the tail cone is labeled correctly.

  12. #12
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    Default Re: Tom Woods NP242 SYE

    Sorry for the delay, just been busy...

    So I realized the issue about 6pm Friday night, and Tom Woods was closed. I sent an e-mail explaining that I thought the problem was and left a voice mail as well.

    I received a call from Mr. Tom Woods the following Monday morning. He said they obviously had made a mistake and after apologizing he wanted to know if I needed the correct part immediately. Was it holding me up, in other words. I told him no that some parts I had ordered for my transfer case had not come in last week, so I wasn't going to work on the SYE install until the upcoming weekend. He verified that it would be okay to ship the part regular (like the prior shipment) and I said of course.

    So he was very concerned that I didn't have what I needed and wanted to figure out a way for me to have it as quickly as possible. I was only answering questions here, no inquires from me about why, and how. Tom was on top of all of that. And people, that's the way it should be from any vendor you deal with.

    So Thursday I received the replacement part.



    Friday morning I e-mailed a thank you to Tom Woods, letting him know that I had received the replacement part and it looked like the tail cone I needed. I received a phone call from Tom Woods about an hour after that and he verbally checked that I had the right part over the phone.

    In the updated invoice he sent me (no additional charges) he included a return shipping not only for the wrong part but the rest of my 400 in core stuff I needed to return for credit. So my out of pocket cost on this venture will only be Tom Wood's excellent goodies and no shipping. Shipping to me was free, I was only going to have to pay shipping back on the core return.

    Oh and some of the parts I already had...





    So just I have read many times before, Tom Wood's takes care of his customers. Thanks Tom, and of course all the people that work for him that help make their products.

    BTW, The tail cone had the right words on the label it just didn't fit the part it was attached to.

  13. #13
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    Default Re: Tom Woods NP242 SYE

    I'm glad to hear that Tom Woods' customer service is truely as good as I contiue to hear that it is.. I can't wait to pick my SYE & DS up!!
    FORMER GREEN XJ CLUB MEMBER
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    DOING SOMETHING JUST BECAUSE YOUR BUDDY DOES IT THAT WAY MAKES AS MUCH SENSE AS SHARING TOOTHBRUSHES

  14. #14
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    Default Re: Tom Woods NP242 SYE

    Well I finally got my lazy ass out in the garage. It wasn't so bad since it wasn't 100 degrees out today.

    I learned some more about the NP242, specifically needle bearings! Fortunately I had some new ones in a NP242 kit that I have purchased previously from Mark, Payless 4x.

    I also, for some strange reason, had purchased some heavy grease today which was perfect for holding the needle bearings in place.

    Oh this was a replace the 3rd stretched chain, drive and driven gears, AND install the SYE.

    Mission accomplished!

    Here is the number 1 reason I went with Tom Woods SYE solution instead of an inexpensive hack and tap. Yes it's basically the same thing but I don't think the shaft is THIS short on the hack and tap.



    This gives you an idea how far this shaft stuck out. Of course it's purpose is to act as the slip, but look at the Tom Woods replacement.







    I haven't removed the 1" transfer case drop yet. I wasn't sure if I had 4 of the shorter bolts I needed. I'll have to pull one off of the 99 and then get 4 grade 8 bolts. I may go ahead and replace the transmission mount at the same time. You know after Ray's radiator damaging fun.

  15. #15
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    Default Re: Tom Woods NP242 SYE

    Why am I getting vibrations now?





    It looks like to me the transfer case is a little low, but not a lot I can do about that.

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