Just got finished changing the rear output shaft seal on my '01's 242 transfer case. What an experience finding the right seal. The ONLY place that was able to FINALLY come up with the right part was NAPA. After checking about half a dozen seals on the shelf the parts guy had a 'help' number he called. They told him to try seal number 18108. This turned out to be the correct one. The original one (which shows on thier web site) was 18758. Wrong one. I tried several other auto parts stores and not one of them was able to cross reference the NAPA# 18108 to anything they had. Even after pulling out the book (BCA seals) they had no listing for that year transfer case seal; Although they did have a listing for the rear output shaft bearing.
What I learned (along with others' advice):
1) When removing the drive shaft, carefully remove JUST the front band that is holding the bellows. Use a zip tie in it's place to secure it when finished.
2) Follow others' advice and chisel off the slinger and get a new one from the dealer for about $5.00 PN: 05016615AA
3) Seal gets tapped in with a light hammer. No need for any fancy installers. To install the new slinger, I used a piece of 1 1/2 inch PVC pipe over the output shaft and whacked on it with a dead blow hammer. Put T/C in neutral so you can spin the output shaft and make sure the slinger is going on straight. Be sure not to whack it on too far though, or it will scrape against the T/C
4) As long as you have the drive shaft out, change the u-joints.
5) Splines on output shaft had almost no grease on them, I read (here I think) to put anti sieze on them before re-installing (which I did)
Hope this saves anyone else with a '01 & a 242 T/C some trouble
What I learned (along with others' advice):
1) When removing the drive shaft, carefully remove JUST the front band that is holding the bellows. Use a zip tie in it's place to secure it when finished.
2) Follow others' advice and chisel off the slinger and get a new one from the dealer for about $5.00 PN: 05016615AA
3) Seal gets tapped in with a light hammer. No need for any fancy installers. To install the new slinger, I used a piece of 1 1/2 inch PVC pipe over the output shaft and whacked on it with a dead blow hammer. Put T/C in neutral so you can spin the output shaft and make sure the slinger is going on straight. Be sure not to whack it on too far though, or it will scrape against the T/C
4) As long as you have the drive shaft out, change the u-joints.
5) Splines on output shaft had almost no grease on them, I read (here I think) to put anti sieze on them before re-installing (which I did)
Hope this saves anyone else with a '01 & a 242 T/C some trouble