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Unread 06-24-2004, 08:51 PM   #1
jamescell
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A tip for the 242 swap

I know it's one of the most common swaps, and there are tons of write up's, but they are all missing one important step. I was doing the swap all was going well, I had to swap the input from the 249 to the 242. Had it all set tightened the last bolt and all of a sudden the case made a loud cracking noise. Yes I had cracked the case. Apparenty when you swap the inputs you have to swap the input bearings as well. The original 242 input bearing were slightly bigger than the 249's causing the internals to be too long for the housing.

So now I'm stuck looking for the rear housing, anyone have an idea wher I could find one?

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Unread 06-24-2004, 11:55 PM   #2
Swamp Boy
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??? I never had that problem..

Dont know where you could get another case .. (The 249 back wont fit I assume?)
It would suck to have to buy another case just to get the back ..

Good luck..
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Unread 06-25-2004, 12:01 AM   #3
jamescell
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at first i thought it would fit, but there is an extra hole in the 249 case. any one do a 242 to 231 swap and save the 242?
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Unread 06-25-2004, 12:54 AM   #4
Swamp Boy
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I just swapped the 242 for a 231D.. But my 242 was trashed.. IT kind of Exploded.. I did not keep the rear housing.. Sorry..

Maybe someone else did.. How bad is it busted? Would it be repairable with some liquid steel or something??
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Unread 06-25-2004, 07:31 AM   #5
jamescell
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well the crack is about 4" long, it didn't crack the mating surface at all. Do you think that would hold up for the life of the case?
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Unread 06-25-2004, 08:47 AM   #6
kampster
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Quote:
Originally Posted by jamescell
well the crack is about 4" long, it didn't crack the mating surface at all. Do you think that would hold up for the life of the case?
Simply have it welded by someone who has the equipment to weld aluminum.
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Unread 06-25-2004, 10:12 AM   #7
jamescell
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Quote:
Originally Posted by kampster
Simply have it welded by someone who has the equipment to weld aluminum.
great idea I'm taking it to the shop right now
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Unread 06-26-2004, 02:02 PM   #8
JohnAH
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Quote:
Originally Posted by jamescell
great idea I'm taking it to the shop right now
If takeing it to the shop doesn't work out for you, you can always do the repair yourself, here are 2 sites that sell the high tech aluminum repair rods:

http://www.aluminumrepair.com/

http://www.durafix.com/

Also you should contact those that wrote up the how to for the swap, so they can edit it accordingly.
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Unread 06-27-2004, 12:51 PM   #9
jamescell
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wow that's some pretty crazy stuff. I never though it could be so easy as soldering.
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Unread 06-29-2004, 12:13 AM   #10
95Orvis
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Quote:
Originally Posted by jamescell
wow that's some pretty crazy stuff. I never though it could be so easy as soldering.
Hey Jamescell,

Give George over at TransferCases Unlimited a call or send him an email. He's a great guy and was incredibly helpful to me when I just went through my 242/249 swap. I would almost guarantee that he has a part he can ship you almost overnight if you really need it. He rebuilds about 100 TCs/week. My TC was shipped in 2 days to my local mechanic. HE KNOWS HIS STUFF.
Here is his contact info.
GEORGE
TRANSFER CASES UNLIMITED
LONG ISLAND NY
CELL 516 658 1440 SHOP 631 226 1448
email: TRANSFERCASEGEO@aol.com

Last edited by 95Orvis; 06-29-2004 at 12:15 AM..
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Unread 06-30-2004, 06:43 PM   #11
jamescell
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well i finally put the case back in, the weld works. But I think the bearings are shot. My jeep makes a sound very similar to a front wheel drive car that's backing up. how frustrating!
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