96 transfer case swap - JeepForum.com
Search  
Sign Up   Today's Posts
User: Pass: Remember?
Advertise Here
Jeep Home Jeep Forum Jeep Classifieds Jeep Registry JeepSpace Jeep Reviews Jeep Gallery Jeep Clubs Jeep Groups Jeep Videos Jeep Events Jeep Articles
Go Back JeepForum.com > Models > Jeep Grand Cherokee & Commander Forums > ZJ Grand Cherokee Forum > 96 transfer case swap

JK Vent Covers - NalinMFGRing & Pinion's, Lockers, 4340 Axles, Install Kits, BaTJ 5.25" Speaker Adapters - NalinMFG

Reply
Unread 06-13-2014, 12:41 PM   #1
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
96 transfer case swap

Hey guys I got a bit of an emergency. I got a 96 grand with a quadra trac all wheel drive t case. Long story short. The cv went on the front drive shaft and tore the t case apart. So I bought a 95 for a parts jeep that has an np249 all wheel drive t case. I'm trying to put it in my 96. But I just noticed the shaft that slides into the transmission is over a half inch longer than the transfer case that came out. Basically I'm asking what are my options here. Do I need a different t case? Or can I easily swap out the shafts of the cases? Thanks guys

black97grand is offline   Reply With Quote
Unread 06-13-2014, 12:44 PM   #2
misfit77
Registered User
1996 ZJ 
 
Join Date: Sep 2012
Location: tucson, az
Posts: 616
Not sound advice but I am sure people cut their output shafts on the transfer case when installing slip yoke eliminators.

I don't see why you can't cut yours. Do the splines match?

It's possible to have someone rebuild your drive shaft to length. Local place charged me 110 and the shaft was beefier than stock.
misfit77 is offline   Reply With Quote
Unread 06-13-2014, 12:46 PM   #3
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
The problem is on the input shaft to the transfer case. Where it mates to the transmission. The shaft that slides into the transmission. They are both 23 spline. Like I said one is a half inch or so longer.
black97grand is offline   Reply With Quote
Unread 06-13-2014, 12:50 PM   #4
misfit77
Registered User
1996 ZJ 
 
Join Date: Sep 2012
Location: tucson, az
Posts: 616
Crap. Sorry. Cutting may not be wise.

Wish someone could validate that you could swap shafts but that means more work.
misfit77 is offline   Reply With Quote
Unread 06-13-2014, 01:43 PM   #5
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
Is that shaft part of the viscous coupler?
black97grand is offline   Reply With Quote
Unread 06-13-2014, 01:54 PM   #6
HighLonesome
Belief In All Things Jeep
 
HighLonesome's Avatar
1995 ZJ 
 
Join Date: Feb 2005
Location: New Mexico
Posts: 5,502
Ingest the first page
http://www.jeepforum.com/forum/f13/t...-np242-685644/

You have 23-spline long (1.55") input shaft from the 95 V8. What you need is the short (.840") input shaft for your 96. Then there is the gear cut change made in 95? that I don't understand the effect of. But I'm sure the answer is somewhere in that thread.
HighLonesome is offline   Reply With Quote
Unread 06-13-2014, 02:06 PM   #7
94cherry
Registered User
1994 ZJ 
 
Join Date: May 2014
Posts: 218
Quote:
Originally Posted by black97grand View Post
Is that shaft part of the viscous coupler?
No the input shaft that slides into the trans is a separate piece from the VC. You have to take the TC apart and either put the the input shaft from your 249 into the donor 249 or just take the VC from the donor to put in your case which IMO would be the easier way to go.
Also how many miles are on the donor case? If its over 100k you might just want to go to the NP 242 or 231 because most VCs go bad at about 150k.
I did the 242 and love the results.
94cherry is offline   Reply With Quote
Unread 06-13-2014, 05:45 PM   #8
Technohead
Old School
 
Technohead's Avatar
1998 ZJ 
 
Join Date: Dec 2008
Location: Exeter, RI
Posts: 6,577
Find a t-case from a 96+ Grand Cherokee or Cherokee.
Technohead is offline   Reply With Quote
Unread 06-13-2014, 05:53 PM   #9
SuperStew11
Registered User
2000 WJ 
 
Join Date: Mar 2013
Posts: 184
The gear cut change was done part way through 94 so if the new TC was built in 95(check the tag) then you can swap input shafts, if it was built in 94 you'd have to pull out both inputs and check the gear cut, and if it was built in 93 then you can't use it at all
SuperStew11 is offline   Reply With Quote
Unread 06-16-2014, 02:04 PM   #10
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
Thanks for all the help I'm going to get to work on it more today. I have the short shaft out because it was easy considering half of the transfer case was gone. It's the shaft inside of the planetary thing. I'll check to see when the case was built.
black97grand is offline   Reply With Quote
Unread 06-16-2014, 02:12 PM   #11
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
Quote:
Originally Posted by 94cherry
No the input shaft that slides into the trans is a separate piece from the VC. You have to take the TC apart and either put the the input shaft from your 249 into the donor 249 or just take the VC from the donor to put in your case which IMO would be the easier way to go. Also how many miles are on the donor case? If its over 100k you might just want to go to the NP 242 or 231 because most VCs go bad at about 150k. I did the 242 and love the results.
The donor case does have 200k on it. But it is going Into a pretty much off road only jeep. But if I were to get a 242 or 231, which would you prefer and how much could I expect to pick one up for?
black97grand is offline   Reply With Quote
Unread 06-16-2014, 02:29 PM   #12
94cherry
Registered User
1994 ZJ 
 
Join Date: May 2014
Posts: 218
Quote:
Originally Posted by black97grand View Post
The donor case does have 200k on it. But it is going Into a pretty much off road only jeep. But if I were to get a 242 or 231, which would you prefer and how much could I expect to pick one up for?
If for mostly off road the 231 is the better choice. I picked my 242 with 128k on it for $100 bucks then another $100 for seals, RTV sealent and fluid.
94cherry is offline   Reply With Quote
Unread 06-16-2014, 02:39 PM   #13
black97grand
Registered User
 
Join Date: Nov 2011
Posts: 45
I'm probably going to sound stupid. But I'm just curious, since it is an off-road only jeep, is it possible to weld the VC together. Or will I just start shearing stuff?
black97grand is offline   Reply With Quote
Unread 06-16-2014, 02:39 PM   #14
OverlandZJ
Registered User
1998 ZJ 
 
Join Date: Oct 2012
Location: Bristol, Pa
Posts: 928
What condition is the original transfer's front case half and input assembly in? You could swap the donors guts into the original front half if usable... but you still end up with a 200K mile viscous coupler. Unless of course someone replaced it..

That'd be your immediate fix with parts onhand. Can you share pics?
__________________
Beware Mike934- Thief named Kamaran Wain..Google it.
OverlandZJ is offline   Reply With Quote
Unread 06-16-2014, 02:50 PM   #15
94cherry
Registered User
1994 ZJ 
 
Join Date: May 2014
Posts: 218
Quote:
Originally Posted by black97grand View Post
I'm probably going to sound stupid. But I'm just curious, since it is an off-road only jeep, is it possible to weld the VC together. Or will I just start shearing stuff?
VC is a sealed unit made up of a series of clutches in a fluid.
94cherry is offline   Reply With Quote




Jeep, Wrangler, Cherokee, Grand Cherokee, and other models are copyrighted and trademarked to Jeep/Chrysler Corporation. JeepForum.com is not in any way associated with Jeep or the Chrysler Corp.