Don't rebuild it, bearing kit around $100-125 chain $150 viscous coulper $400, swap in a np242 or np231.
95' Jeep Grand Cherokee Laredo, 148k, 5.2, NP242, 46RH, 4" RC lift, all new adjustable ca's(2 IRO front uppers and the rest RC adjustables), nitro shocks, JKS TB's, Jet Chip, Dynamax cat back, Magnaflow cat, GTP hood vents. 31" Pro Comps with Rock Krawler "D"s. Westin brush/grill guard with Hella 500s, 411's, Solid diff covers, detroit locker rear, power lock in front, SYE and Tom Wood's front/rear shafts, RE discos, BPE's, d-rings front and back, factory tc and rad skid, hitch, Sliders next.
03' Jeep Grand Cherokee Laredo, (wifes Jeep) 99k, 4.7 5 speed auto, K&N, KYB shocks, drilled-slotted rotors, All the toys.
2000' Ford Superduty, F250, 7.3, 198K, 37's, too much to list.
Ok that would be better then due to the fact we mainly use as a daily driver. When you buy the 231 or 242 does a new shifter come with it to tell if you are in 4 hi or lo and what about locking the hubs?
Any ideas where I can find parts to rebuild my 249 tc?
I didn't read the whole thread yet, but most people will tell you not to rebuild the 249 because of the cost. Yes it is true, the 249 VC is expensive to replace. I was in the same situation your are in now. I couldn't decide between cashing out and buying the 249 rebuild kit or doing a swap to the 242 as most people will do.
I like my 249 and the way it works so i decided finally to rebuild, i purchased everything from Nick Kolak, he is on here quite frequently. I paid $500 for my overhaul kit, that is the VC, chain, and seals and all.
The kit just arrived this afternoon. I'm hoping to rebuild it this weekend. I know its a lot of money, but i like the way the 249 works and its never failed me in the snowy/icy winters.
note: the 4wd function in the 249 and 242 are NOT the same. the 242 is not a "locked" tc like the 249 in 4wd. in the 242 your will have to use parttime 4wd to have the locking action, which in this model is not good on the pavement.
And the 242 does have a full-time 4WD mode which will get you through just about any on-road conditions you may encounter, if it gets really rough or if you're going off-road, you can just pop it in to part-time mode.
I agree that the 242 does lack the "handsfree" convenience of the 249 though.