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!
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.
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.
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..
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
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.
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?
'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.