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Unread 10-27-2009, 03:49 PM   #1
CDRFunkmeyer
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1994 ZJ 
 
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Location: Bellflower California
Posts: 78
NP249 to NV249 Transfer case swap

So I have a 94 zj w/a 249 that's gotten old, crunchy and has lots of play, plus It was glued shut by a genius mechanic who told me to never to open it because he epoxied the case back together after they ran it into a rock.

So I gotta Replace it...
went to my local junkyard. found a happy looking 249 (NV I guess) in a '97 zj. I get home, it looks the same as the one in my car.

I remove my 249. And when comparing them both I find that the input shaft on the newer one is about an inch shorter thatn the input shaft on the older one.

Question:
does it matter if the input shaft is shorter, so long as it makes a seal?

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Unread 10-27-2009, 04:11 PM   #2
QuadraTokn
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You got a transfer case from a 4.0 instead of a 5.2.

You can swap the input shafts over, but you have to take the whole t-case apart for that, and you'd probably need a different length rear drive shaft too.

Im not sure what you mean by "makes a seal", but im pretty sure that the splines wont even mate up.
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Unread 10-27-2009, 04:20 PM   #3
CDRFunkmeyer
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Yup it was out of a 4.0. Might be screwed there.

Anybody know more about (if the splines match) is it acceptable to have a shorter connection between the Trans and the TC?
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Unread 10-27-2009, 05:26 PM   #4
ZJPunk98
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2002 WJ 
 
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You can swap out the input and output shafts. there are many writeups on here about that. Just search 249 to 242 tc swap. this should get you what you need. i was looking at them the other day.
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98 ZJ 5.2L JGC Limited Sold
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Last edited by ZJPunk98; 10-27-2009 at 05:27 PM.. Reason: note: i realize you are installing a nv249, but the process is the same and easier to find under my search suggestion
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Unread 10-27-2009, 07:03 PM   #5
CDRFunkmeyer
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Hym; if the transfer case is the same size, and it's housing bolts to the same location, why would I need another propeller shaft?
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Unread 10-27-2009, 08:36 PM   #6
ZJPunk98
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some of the posts you may read when you do a search will give you more info, but the short of it is that some of the input shafts a different lengths. you will need the correct length input/output shafts for everthing to work/fit properly.
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Unread 10-27-2009, 10:31 PM   #7
highlyuncntered
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Don't forget the gear cut. Somewhere in the '94 to '95 area New Venture/Process changed the gear cut in the planetaries. If you have two different gear cuts, there is gonna be a lot of noise, like a high-pitched whining, when you are driving. Nobody has narrowed down exactly when the gear cut changed. I would personally try to find a 249 out of a '94 or earlier ZJ and swap your input shaft in to that, or a V8 input set from '96 or later so that you can keep the Low Range lock feature that was implemented in '96. Good luck to you, though.
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Last edited by highlyuncntered; 10-27-2009 at 10:32 PM.. Reason: gettin' specific
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Unread 10-28-2009, 12:14 AM   #8
ratmonkey
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Gear cut changed in 95 you'll need to use the whole front half of your old case to use any of the new case.

The case will mate up and engage the splines of the tranny output, but is not long enough to engage the oil seal. For reference, 93-95 v8 had the 1.550" exposed input shaft, 96-98 had the .840" input as did all i6 grands.
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Unread 10-30-2009, 12:39 PM   #9
CDRFunkmeyer
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Ah, the gear cut got me. I took that NV249 back and pulled a NP249 out of a 93GC with 125k on it. The guys at the junkyard were really understanding. Now it feels great! no more crunching in my TC. Now I just need to get the rear driveshaft lubed up better so it won't click when I take off from stop signs.
Thank you so much for all of your help guys, I was not going to find out about the gear cut being changed from the chilton's manual. lol.
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