249 to 242 swap in progress. - JeepForum.com

 
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post #1 of 14 Old 07-28-2012, 09:35 PM Thread Starter
airwolf9090
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249 to 242 swap in progress.

I just now got around to doing my swap even tho i had the 242 case for months... Today i dropped out the 249 and tomorrow i am putting in the 242. I got the input shaft seal for the case and the output shaft seal for the tranny. And i am having some thought so i thought i would ask i looked over the swap tread afew times but i am still worried.... The 242 case is out a 96+ I6 ZJ, Date code on T-case shows a 96 case same as the date code on the 249. But the thoughts i am wondering is do i have to swap anything between the 2 cases. I am talking about the sensors. Besides breaking off a bolt in the rear end's yoke, The 249 came out easy and nolonger will it spit it's blood on the underside of my ZJ! as it bled out for it's last time on the ground!

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1996 Jeep ZJ Orvis
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post #2 of 14 Old 07-28-2012, 09:45 PM
jtackerman28
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How did you get the top bolts?? Just curious because I have to do the seal on the output of the tranny

3.5 re lift, double sheer front tb, 31" wrangler duratecs
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post #3 of 14 Old 07-28-2012, 09:48 PM
ahuf
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I believe you will need to swap out the 249 input shaft to the 242. Only if the 242 shaft is a different length. I could be wrong so get a second opinion.

I have not done this swap but will be in the coming month/s.

Looks like it will be fun. Make sure to post pics as you go. The more info the better.


1998 Jeep Grand Cherokee 5.9 Limited 4x4 :: 46RE, 249, MSD ignition, PO e-fan conversion to a different e-fan, 3.73 gears
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post #4 of 14 Old 07-28-2012, 10:11 PM
pincheburro956
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I think u are all right. As long as both tcases are post 96, IIRC from the tcase swap thread...

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99 WJ, 2" BB, 245/75/16 Falken Rocky Mountain ATS.
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post #5 of 14 Old 07-28-2012, 10:13 PM Thread Starter
airwolf9090
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Well how i got the top bolts i just lowered the jack that was holding it up low enough to get a wrench in there...

as for the input shaft i don't think i have to change it. I figured from the info in the swap thread it would be the same in these two cases....

1996 Jeep ZJ Orvis
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post #6 of 14 Old 07-28-2012, 10:45 PM
jtackerman28
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thanks for the info. Are there two seals that need to be changed between the trans and transfercase?

3.5 re lift, double sheer front tb, 31" wrangler duratecs
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post #7 of 14 Old 07-29-2012, 09:57 AM
Crasher
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As long as the 242 came from a 96 "ZJ", the inputs are the same. All 96-98 ZJs and 97-2001 XJs have the same input shaft. If the axle gear ratios between the donor and your ZJ are the same, nothing needs to be swapped. If they are different, then switch the speedo gears so you will have correct speed indicated. The harness should plug in and just swap the two wires behind your VIC and you are good to go.

2005 LJ, 112" wb, RJ60's, ARB lockers, Fox Coil overs, 40" Creepies
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post #8 of 14 Old 07-29-2012, 10:43 AM Thread Starter
airwolf9090
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Okay thanks. Just what i needed to know. I don't know the gearing of the donor Heep but i track speed by GPS so if its off i will change out the speedo gear.

1996 Jeep ZJ Orvis
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post #9 of 14 Old 07-29-2012, 10:46 AM Thread Starter
airwolf9090
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Now i just got to get it back together and figure out how to get the a bolt out the rear yoke where i had one break off when i was pulling the drive shaft

1996 Jeep ZJ Orvis
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post #10 of 14 Old 07-29-2012, 10:57 AM
Crasher
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The other thing you might have to do is modify your rear driveshaft length. Some say they didn't have to, but most say they did. If your ZJ has the 44a rear axle, I would like to know the distance between the u-joints of the rear shaft when you are done.

2005 LJ, 112" wb, RJ60's, ARB lockers, Fox Coil overs, 40" Creepies
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post #11 of 14 Old 07-29-2012, 08:40 PM Thread Starter
airwolf9090
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Well its about done. Just got to adjust the linkage and yea the adjustment bolt came out but the adjustment bar is rust/dirt welded together so its soaking in PB blast, and get the dang bolt out the rear end yoke! I been thinking would it be fine to drive the 7miles to town with only the front drive shaft to my friends shop and let him get the bolt out? As for the driveshaft i gotta find a ESY Driveshaft because the one i picked out is bent! and the one out of it is a ISY so its too long..

1996 Jeep ZJ Orvis
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post #12 of 14 Old 07-30-2012, 11:52 AM
Timo_90xj
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Yes, you can drive the Jeep with the 242 (or 231) t-case with only front driveshaft in place; with a 1996-> TC you should have an external slip yoke IIRC so it won't spit out the TC fluid when rear DS is removed.

Keep it in 4hi, otherwise you won't be moving anywhere

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #13 of 14 Old 07-30-2012, 12:50 PM
Crasher
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You can use your same driveshaft from the 249, but as you say, it will have to be shortened. The slip yoke end of the shafts are the same, but the 242 has a boot to cover it instead of the cone with a seal.

2005 LJ, 112" wb, RJ60's, ARB lockers, Fox Coil overs, 40" Creepies
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post #14 of 14 Old 12-14-2012, 10:27 AM
MikeyM
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Hi guys,
Hi guys, I realize this is an old thread but it is the newest so I'm hoping to get a bit of help from the OP. I'm getting ready to do this swap, too, and have found a donor from a '97 ZJ. Since I have a 4" lift, I was wondering if the rear DS would need to be shortened at all? I know TAZ swapped a 242 into his 5.9 and it was a direct bolt in; no modification needed on anything... I was wondering, since I have a 5.2 if the same would be true for me. Perhaps not since the 46RE might be a hair longer than the 44RE - I don't know. But I suppose I could just measure the length of the rear half of the case to see if the DS needs to be modified. I was hoping not and was thinking that since I'm lifted, the front of the SY on the rear DS would end up in about the same position on the TC output shaft as a non lifted rig. Any thoughts?

Thanks,
Mikey

'98 ZJ 5.2L V8, full intake, exhaust, & ignition mods, Rusty's 4" coils with front TB conversion, rear ORGS TB, OME long travels & SS, Tera QDs, Yakima rack w/goodies, BFG 31" MT/KMs, full skids, front and rear diffy guards, Donavee rear swing-out tire carrier. 213k, 18-19 hwy.
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