[sk8142]

I wrote this up for future people searching for info on the swap.

A few tips on the 242 swap

I recently did the 249---> 242 swap into my 93 grand wagoneer using many of the write up’s on this forum as well as others and they helped out a lot but there were a few things I wasn’t sure on until I took the TC’s apart. This is just a few things I found that helped.

1) In the stickies they mentioned a lot of snap rings but never lock rings. Well upon taking the TC’s apart I found a lot of lock rings. So buy a good set of lock ring pliers as they will save you time and stress.




2) When reading the stickies about disassembling the 242 it did not mention the lower shift fork pin. I spent about an hour just trying to pop out the pins/roller bearings that shift the TC into gear with no success. I found a thread that mentioned pulling a small black rubber plug just above the TC shifter linkage and inside there is a small retaining pin that holds the lower shift fork to the shaft.

Using a #1 screw extractor I pounded it into the small pin then used vise grips to pull up and rotate the pin until it came out. This made removing the shift forks much easier.



3) When I was installing the shift linkage I ran into a problem adjusting it. The method I used to solve this was to manually put the TC into 2WD with the 13MM bolt on the shifter linkage loose then went inside the cabin and moved the TC shifter all the way forward. After this, go under to the linkage and tighten that 13MM bolt. That worked out for me.



4) The TC gear position ( 2WD, 4PT, 4FT, N, 4LO) sensor on the 249 is on the front side of the TC where as the sensor on the 242 is on the back side by the rear output and speed sensor. Well the plug for that sensor won’t reach back to the 242 position sensor. I’m still searching for a part/harness plug adapter that will reach or I might just cut the wires and extend them 6” or so.
This is the gear sensor on the 249


5) when installing the input shaft and planetary gears from the 249 make sure you set them in there flat and use a rubber handle hammer to tap it down into place. It takes a few taps to seat it completely. The pic below shows the shifter fork assembly and how they go in.


Hope this helps out anyone in the future planning to do this swap.

[j.love]

Here is a little added info and pictures of item #2 the roll pin for the shift forks on the 242. hope this helps somebody


The following was pulled from a thread I started when I ran into the same issue...

This is the tread.
http://www.jeepforum.com/forum/f13/242-disassembly-410485/

Originally Posted by RiPPiNiTuP7

there's a rubber plug on the outside of the case, if you pop it off and look in the hole you will see a roll pin (if you don't wiggle everything a bit to get it to show at the hole) holding all that crap in there, if you get a #1 screw extractor and screw it in enough to bite into the pin, you should be able to easily slide it out with some pliers. that's it, now finish the disassembly.

Originally Posted by j.love

I got the tool I needed I only had an easy out.. and didn't have an extractor.. so I needed to pick one up..for anybody trying this here are a few pics...



the tool!





in action..




pin removed..






.

[sk8142]

ahh good info. I didn't find that thread when I was searching for info

[BLACKzj52]

dang, the inside of the 242 looks spotless!
great info also

[Sporer65]

What year 242 did you use? If it was a 23 spline that came with 92 and up I think, you shouldn't need to swap over all the internals.

Also, did you happen to measure the input shaft? I'm wondering if our Wagoneers are different then normal 5.2Ls.

[sk8142]

The TC was out of an 89 xj with unknown milage. It had a 21 spline input shaft on it. I think it was recently rebuilt because there was black marker writing on the gears along with some numbers etched into them. The wagoneer gear is the same as anyother GC I believe.

[j.love]

Originally Posted by Sporer65

What year 242 did you use? If it was a 23 spline that came with 92 and up I think, you shouldn't need to swap over all the internals.

Also, did you happen to measure the input shaft? I'm wondering if our Wagoneers are different then normal 5.2Ls.

In the early 90's there was a switch between the 21 spline and the 23 spline. where that cut off is, I dont know.

My 5.2 needed the long input shaft and my donor 242 out of an XJ had a short input shaft. I think most of the 6cyl. use the short input shaft. and the 5.2's use the long. But I'm not 100% on that info.

[micifus]

did you replace the rear trasmission seal?

[j.love]

Originally Posted by micifus

did you replace the rear trasmission seal?

LOL

I guess that deserves mentioning too!

Note: Replace transmission seal while you have the TC out!

[sk8142]

Originally Posted by micifus

did you replace the rear trasmission seal?

Sure did. I also replaced the rear seal in the tail of the TC for the DS.