Excited to share this and hope it helps someone out to have a first hand look at the job. I'm in the process of a 249 to 242 transfer case swap and I'm making a video series out of it! Here it is. Leave a comment and let me know what you think. Thx!
Nice job on the video. It's great that you share the special tool set-ups to get to difficult fasteners. Despite my already having a 242 in my ZJ, I'll subscribe to learn a bit about the removal and replacement. Cheers.
I have a few tips from removing the tcase three times:
1. tool to remove 14mm tcase-to-trans nuts.
This, plus some extensions, is easy to make with just an angle-grinder and a big socket:
2. to make a tcase jack unbolt the circular flange plate from a regular floor jack, drill holes, and bolt on a big 2.5"x20"x20" block of wood. Some wood spacers will then let you support the tcase square.
3. disconnect the trans shift lever mechanism where it pivots on the frame -- it will break if you lower the trans too much. but if you do step 4 and watch carefully. then you will probably not lower it enough to cause damage.
4. no need to remove the trans cross-member. look at the 4 cross-member-to-frame bolts. loosen all four a little, replace one with a 3" long bolt. now remove it's brother -- now you can lower the trans a little without having anything in your way holding it up. it will just hang on the long bolt
5. remove the shift lever on the left side of the tcase by removing its bolt. this is easier than trying to pry off the nylon pivot. those nylon pivots break easily too.
There's a big sticky at the top of the forum that explains all this . . .
There are three t-cases that came in the ZJ.
NP249 - two modes: 4 All Time, and 4lo. This was the only case behind the V8's and is common behind 4.0's as well. There are really two versions, the first gen (93-95) and second gen (96-98). Both versions use a Viscous Coupler (VC) to lock the driveshafts together when slipping occurs. The first gen is split 50/50 all the time and has no lock in low. The second gen is rear weighted 10/90 and is locked in low. NP242 - four modes: 2wd, 4 Part Time, 4 Full Time, and 4lo. Same basic case all years, driveshafts are locked together in 4PT and 4LO. The 242 uses an OPEN differential in the case to provide a 4FT mode that can be used on pavement. In 4ft the 242 will allow one wheel to spin in low traction situations. NP231 - Physically smaller (increased ground clearance) and simpler than the other cases. This is the same case found in Wranglers. Modes are 2wd, 4hi, and 4lo. Neither 4wd mode can be used on pavement (well, neither *should* be used on pavement).
All three cases use the same 2.72:1 planetary reduction in 4lo. The VC in the 249 wears out over time and becomes permanently locked, but can be replaced.
So I finally actually got a chance to sit down and watch this video. Question. it seems like you didn't even bother to remove the crossmember, just the transmission mount through bolt. Did you do anything with the crossmember at all? it looks like you might have loosened the bolts, but I'm not.
Also, is the 95 you're working on lifted at all? I can see the wheels are still on the ground chocked, but does the Jeep sit stock height? Up country height? Lifted?
Just following up. Finally got the 249 input shaft removal video done. Thought I'd throw it on this thread. Kinda a fun video and I find a surprise when I open the 242 case. Check it out
249 input shaft swap and 242 rebuild video done. Didn't remove the roll pin on this one. It came out with a little encouragement. Check it out and let me know what you think. Thx!
And here's the 242 install video!!
Almost done. Just have to finish up the shift linkage and bezel video. Then the complete video series will be done!!
Hope it helps with anyone doing this swap.
Thx!
yes, i bought powerdirector on your recommendation and i've gotten to like it
BTW this tool is what one is supposed to use to get the retaining clips off
actually i would go for an even bigger one -- problem is there is no universal name for this type of pliers, so it is difficult to search for on ebay/amazon
Here's my last 2 videos in this series. The shift linkage, bezel and display. I hope this series helps some folks out. Was fun making it. I plan on putting all the videos into one Grand Poobah from start to finish. Grab your popcorn
Shift Linkage
Bezel and Display
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