Ive been looking into some armour for my next steps. I like the warn transfer case skid and I have found a used one for sale. I have concern about 2 things. Firstly on the Warn website it states that their skid does not work with the 242, which I have. I had never head this before, but as the 242 is somewhat rare this could be why. I do however have a 1" transfer case drop. This could potentially solve my first issue. However it may cause another issue. As the skid bolts to the crossmember that is dropped 1" as well as the "frame rail" of the Cherokees unibody. I'm sure it would be easy to put a spacer in place and bolt it up. But would this in turn just create a shovel to grab dirt? I love the idea of some protection but it seems like a bit of a headache for this piece.
I have contacted Warn to see what they have to say.
I don't think 1" is enough room to fit the NV242.
I bought a used TNT long arm lift for my Jeep that was meant for a NV231 transfer case. I ended up cutting a pocket out of the skid plate and welding a fixed cover to go around the transfer case to make room by about an inch, maybe 1-1/8". This is after spacing the entire driveline up into the tunnel by about 5/8" (IIRC) via a spacer at the transfer case mount.
I would say I have around 3/8" - 1/2" of space between the transfer case and the bottom of the new pocket and seems to just clear when the driveline is bouncing around under load when off-road. Working backwards that means the case needs about 2-1/4" if you are pessimistic and assume that the clearance that is there in my configuration is marginal. Maybe you can get away with less but with a stressed aluminum housing I'd prefer not to tempt fate and ensure it doens't touch the cross member under any circumstances.
IIRC there is someone out there making a transfer case skid for the NV242. I don't remember the manufacturer or if it was worth a damn but certainly doing some web searches may provide some further insights.
HTH
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