NP249 to NP242 swap - rear driveshaft
This is probably covered somewhere in the sticky thread but I'll be honest here. I'm too damn lazy to go through 113 pages of the thread to hopefully find what I'm looking for!
I just finished the swap, only to find out my donor driveshaft is WAY too short.
Spent all day on it. All that's left is to adjust the linkage (got the adjustment bolt loose with acetone + ATF mixture, but the rods are rusted together), add fluid, put my skid plate back on, and..... find a new drive shaft.
My jeep is a 98 with the 5.2. Had an NP249 with an internal slip yoke. I bought an NP242 transfer case from a 96 4.0 with an external slip yoke. The junkyard I bought the transfer case from doesn't save drive shafts, so I was SOL there. But my local yard had 4 of them. Long story short they're stuck up pricks (never had a good experience there but they're 5 minutes down the road!) and grabbed a random one off the shelf (not allowing me to measure to pick the longest one), told me it wouldn't work and since I was buying a part that obviously wouldn't work in my jeep they didn't want it back if it didn't fit.
Well you guessed it, it was too short. Measures 28" weld-to-weld going from both the far ends of the welds.
With this shaft installed, it is only engaged onto the splines about 1-1/4".
There is another junk yard about an hour away with a 29.5" ESY shaft. I'm guessing this is the one I'm looking for? 2-3/4" still doesn't seem like a lot on a 4-3/4" slip yoke, but is much better than what I have now. I don't even dare drive my jeep on the road the way it is.
Is the 29.5" shaft the one I want, or am I best to take my original driveshaft (measures 31" W-W), separate it into two pieces at the u-Joint, and put it back together with the ESY end on it? That should give me 4-1/4" of contact between the shaft and slip yoke. Now I'm wondering, is this TOO much? Wondering if I'd have issues during rear suspension up-travel , with the shaft being jammed into the case too far.
The "Mall Crawler" - 1998 ZJ Grand Cherokee 5.2 V8, D44a rear axle, NP242 ESY transfer case swap, 4.5" Rough Country lift, Up-Country skids, 31x10.5x15 Destination M/T, future mods planned.