1993 Volkswagen LT 4x4 - New Process 242J transfer case install

The installation of the Jeep transfer case into my Volkswagen LT 4x4 was fairly straight forward.  I used a 1993 Jeep Cherokee Automatic transfer case.  To make the transfer case work requires swapping the "front side" flanges over from the original Volkswagen New Process 241V transfer case.  The rear drive shaft output was modified using an aftermarket yoke eliminator kit.  The flange on this kit is then redrilled to match the holes in the Volkswagen drive shaft flange.  One of the issues with the 242J is there is an extra position on the selector shaft and there isn't enough travel on the LT's shift leaver to reach all positions.  You have stuck with having either 2H, 4H - unlocked, 4H locked, N or 4H - unlocked, 4H locked, N, 4 low.  Currently I have my in full time 4WD and I have to admit there is a drop in fuel economy and it is hard to steer in parking lots.  I had to fabricate up a shorter Volkswagen style selector shaft on the transfer case as the original Jeep selector shaft is on the bottom and there is no hole in the skid plate for the cable to attach.

1993 New Process 242J - Front

1993 New Process 242J - Rear

1993 New Process 242J - Installed!

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