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Unread 09-17-2013, 10:52 AM   #1
-Otter-
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1996 ZJ 
 
Join Date: Apr 2012
Posts: 63
I'm currently on my second ZJ. My first one was thoughtfully named the "Green Menace" due to having it straight piped. That one crapped out on me so I bought another. This one is different than the first by having the 5.2L, a NP249, and a Dana 44HD rear end.
I bought it bone stock and immediately put 3.5" RE lift on it. Then I bought a set of 31"x10.5" General Grabber Red Letters. So far I have trimmed the front bumper, cleaned up the axles front and rear and re-painted them, changed all my fluids, added a CB antenna mount off the drivers side tail light, made a custom external speaker mount with picnic tablecloth holders, an last but certainly not least joined my local jeep club.
I've driven it for about 5000 miles and I am already set to change the jeep again. Here's my plans:
NP242 t-case swap:
23 spline input shaft
0.840" diameter input shaft
Newish front driveshaft
Newish rear driveshaft
242 shift linkage
242 shift indicator sensor
242 bezel
242 rear output seal-4370N
242 front output seal-3946
242 dual lip input seal-710928
46RE output seal-710058
242 master rebuild kit-52270.1007 (crown #242lmaskit)
2qts ATF
2qts ATF+4

Front axle e-locker with 4.56 Yukon gears:
C-clip
27 spline
7.12"ring gear
Spicer joint shaft swap
Chromoly shafts
New wheel hubs

Rear axle lunchbox locker with 4.55 Yukon gears:
C-clip
30 spline
8.5" ring gear
Chromoly shafts
New wheel hubs
New u joints

And finally BDS 6.5" Long Arm with 35"x12.5" Red Letters.

Please feel free to chime in and offer any advice. I'm looking to start purchasing parts here in a couple weeks so I still have time to makes changes for the better.

Chris (Otter)

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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna

Last edited by -Otter-; 09-17-2013 at 12:51 PM..
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Unread 09-17-2013, 05:06 PM   #2
hotrodjeeper
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1998 ZJ 
 
Join Date: Nov 2010
Location: frisco, texas
Posts: 895
I have BDS 6.5" springs in my 5.9 and they sagged 2 inches and I had to put 2.25" BB
up front to level with the rear. Just a heads up if they sag on you.
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Unread 09-17-2013, 05:43 PM   #3
riot1987
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Join Date: Jun 2012
Location: In your attic, with the squirrels and wrapping paper
Posts: 3,511
You like those Generals? I was going to get some but heard they are a pretty soft tire. Great offroad but heard they tend to wear kind of quick.. True?
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Unread 09-17-2013, 06:57 PM   #4
-Otter-
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1996 ZJ 
 
Join Date: Apr 2012
Posts: 63
Quote:
Originally Posted by hotrodjeeper
I have BDS 6.5" springs in my 5.9 and they sagged 2 inches and I had to put 2.25" BB
up front to level with the rear. Just a heads up if they sag on you.
Well I have the 3" spacers I'm running right now I can throw in if need be. I'm assuming the BDS kit keeps the factory rake, so the spacers would level it if they sag. Correct?
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 09-17-2013, 06:58 PM   #5
-Otter-
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1996 ZJ 
 
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Posts: 63
Quote:
Originally Posted by riot1987
You like those Generals? I was going to get some but heard they are a pretty soft tire. Great offroad but heard they tend to wear kind of quick.. True?
I've only put about 500 miles in mine. But I got mine at the recommendation of a buddy in my jeep club. He's on his second set and he got 50,000 out of his first ones on his DD.
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 09-18-2013, 11:25 AM   #6
JohnnyZJ
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Location: Calgary
Posts: 2,159
claytons long arm kit. you're already spending good money might as well get the best on the market. plus the rear comes with a bridge/truss for the diff. if you are running a 44a might you should truss it anyway. two birds, one stone.



also your front diff isn't a 'c clip' axle. rear is. won't matter with your plan. just an fyi.



go get'r done. sounds like Visa/Mastercard/AMEX are going to like you alot........
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Unread 09-18-2013, 11:41 AM   #7
-Otter-
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Posts: 63
Quote:
Originally Posted by JohnnyZJ
claytons long arm kit. you're already spending good money might as well get the best on the market. plus the rear comes with a bridge/truss for the diff. if you are running a 44a might you should truss it anyway. two birds, one stone.

also your front diff isn't a 'c clip' axle. rear is. won't matter with your plan. just an fyi.

go get'r done. sounds like Visa/Mastercard/AMEX are going to like you alot........
I thought the 30 was a c-clip? Since it isn't that means the shaft seal and bearing are press fit right?

And I thought about doing the Clayton's. It is a very nice kit. However I am buying parts of the kit they payroll deductions thru the dealership I work for. And the Offroad company they work with is a BDS retailer so I get a smoking discount. The guy I'm ordering from is in the jeep club with me and doing some math we figured I'm getting about a grand off the lift itself.
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 09-18-2013, 12:42 PM   #8
JohnnyZJ
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if you get a deal then thats cool. can't argue that.

the D30 is a full floater so no C clips. teh bearings, are the unit bearings on the knuckle which carry the load. there are no bearings pressed on the shaft.

the rear is a semi float and works as you described. and your only locker option on that is indeed the drop in. they are fairly easy to install, but getting the C clips to line up is a *****. lol.

good luck with it!
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92 YJ ~ stage 1; 33" super swampers, 4" lift locked 5 yr plan is 8.8/44 and 37s

RIP 95 ZJ ~ 33s built/longarmed/locked/awesome Feb 2014 ZJOTM winner
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Unread 09-18-2013, 12:59 PM   #9
-Otter-
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Quote:
Originally Posted by JohnnyZJ
if you get a deal then thats cool. can't argue that.

the D30 is a full floater so no C clips. teh bearings, are the unit bearings on the knuckle which carry the load. there are no bearings pressed on the shaft.

the rear is a semi float and works as you described. and your only locker option on that is indeed the drop in. they are fairly easy to install, but getting the C clips to line up is a *****. lol.

good luck with it!
Yes working it through my dealership is bringing the price from about $3500 to $2400.

Thanks for the info!
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 03-28-2014, 05:54 PM   #10
-Otter-
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Posts: 63
Been a while since I posted on here. Put on the Kevins Offroad Radiator Supports Tow Points. It was a very straight forward install. Love having the tow points there. Also picked up a K&N Intake at the JY for $15.
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 03-29-2014, 05:00 AM   #11
Technohead
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If you are building a wheeling rig the forget about the 242 and get a 231. More ground clearance, more aftermarket, simpler, stronger . . .
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Unread 03-29-2014, 05:15 AM   #12
speedbucket
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Quote:
Originally Posted by Technohead View Post
If you are building a wheeling rig the forget about the 242 and get a 231. More ground clearance, more aftermarket, simpler, stronger . . .
He beat me to it....lol^
231 instead for sure
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Unread 03-30-2014, 08:47 AM   #13
-Otter-
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Quote:
Originally Posted by speedbucket View Post

He beat me to it....lol^
231 instead for sure
A 231 is the one that has 2 low correct?
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1996 Grand Cherokee, 5.2L, 46RE, NP249
3.5" RE coil lift, 31x10.5x15 General Grabber Red Letters
Cobra Cb with 4' Barjan antenna
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Unread 03-30-2014, 09:27 AM   #14
riot1987
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Im not arguing that a 231 is the "ideal" case for your rig HOWEVER, I have had my 242 in 2 jeeps one of which was dumped in a pond and left overnight. All Ive ever done with that 242 is change fluid. NO issues whatsoever.
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Unread 03-30-2014, 10:15 AM   #15
PolkaPower
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Quote:
Originally Posted by -Otter- View Post

A 231 is the one that has 2 low correct?
2lo ? lol.
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