Transfer Case Swap Info NP249->NP231 & NP242 - Page 102 - JeepForum.com
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Unread 01-31-2013, 09:17 PM   #1516
zarnold
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1998 ZJ 
 
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Quote:
Originally Posted by Andrewm6097 View Post
I have a 96 zj, 5.2, 44RE, D44a, NP249. I want to swap in a NP242 as they are plentiful in my area. I realise that i have ISY and the 242 will have ESY. Now i have been reading through this thread and some people say its still a direct swap using my original rear driveshaft, others say i would need the rear driveshaft from the donor vehicle, and i also read that i would need to have my driveshaft shortened and balanced. So what is it? I just want to know what im getting into and have all necessary parts before i go and tear the jeep apart as i drive it daily.
If your not lifted then you will need to shorten your driveshaft. Below are the measurements I had:

My 242 donor came from a 96 GC with a 4.0L

My stock rear driveshaft was 34.5 inches (center-line to center-line on u-joint cross), about an 1 inch to long. I wanted it shortened 1.25 inches, but it ended up being shortened by 1.375 (not really sure why).

Anyway, my new driveshaft length is 33.125, and works fine.

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Unread 02-01-2013, 01:08 AM   #1517
Andrewm6097
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Quote:
Originally Posted by zarnold View Post

If your not lifted then you will need to shorten your driveshaft. Below are the measurements I had:

My 242 donor came from a 96 GC with a 4.0L

My stock rear driveshaft was 34.5 inches (center-line to center-line on u-joint cross), about an 1 inch to long. I wanted it shortened 1.25 inches, but it ended up being shortened by 1.375 (not really sure why).

Anyway, my new driveshaft length is 33.125, and works fine.
Awesome, thank you very much. I'm lifted 3 inches. Do you think that's enough to get away with using my drive shaft?
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Unread 02-01-2013, 04:09 AM   #1518
ejschultz
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If you're on stock control arms, no. It would require the same length driveshaft a stock ZJ would require. If you have aftermarket arms, you might be able to make it work. If you have all 4 adjustable arms in the rear, I'd venture to say you will be able to make it work but you might have to push the axle too far back to do it. The rear axle shoul sit slightly forward of the center like of the wheel well.
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Unread 02-01-2013, 05:57 AM   #1519
Andrewm6097
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Quote:
Originally Posted by ejschultz View Post
If you're on stock control arms, no. It would require the same length driveshaft a stock ZJ would require. If you have aftermarket arms, you might be able to make it work. If you have all 4 adjustable arms in the rear, I'd venture to say you will be able to make it work but you might have to push the axle too far back to do it. The rear axle shoul sit slightly forward of the center like of the wheel well.
Alright so looks like I'll have to get shortened. Thank you for your help
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Unread 02-01-2013, 08:28 PM   #1520
98GCLimited
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Well here is some info and pics about the collar in the input on the 93-95 ZJ 231 case.

I needed to remove this collar from the input of the 93-95 ZJ 231 case so I could use it on my ZJ with the newer transmission output shaft. I had to open the case to remove the input collar since it is located behind the splines of the input. (I removed this collar rather than swapping inputs because the input on this particular 93-95 231 case I bought happened to be the correct length .840" for my swap and my 98 249 input had different gear cut than this earlier transfer case so I couldnt swap inputs, I just removed the collar so I could use the 231 input.)

Here are some pictures of the collar (silver ring) behind the splines on the input shaft.





And a picture of the collar removed. I took the case apart and simply tapped the collar out of the input using a socket and a hammer then reinstalled the main shaft bearing back into the input since it comes out when removing the collar.



The collar behind the splines on the input was used on these early 42re transmission output shafts. Not sure why the early ones were like this.



The newer transmission output shafts the splines go the full length of the shaft. Here is my later style transmission output shaft showing the splines going the full length of the shaft.



Just an FYI for anyone else this will end up applying to since I couldn't seem to find any pictures of the collar issue when I was researching.

Last edited by 98GCLimited; 09-10-2013 at 01:51 AM.. Reason: picture links were bad
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Unread 02-15-2013, 05:00 PM   #1521
haightjr
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Just To Make Sure I Am Ok.

I have a 95 ZJ 5.2l with the NP249 with a bad VC and performing the swap. I think I found my new NP242 out of a 92 XJ. Will I have any issues? Will the Input shaft from the NP249 fit? Thanks!

Here is the NP249 Tag:
img_20130215_145539.jpg

Here is the NP242 Tag:
resizedimage951360967277265.jpg
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Unread 02-15-2013, 05:16 PM   #1522
haightjr
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Originally Posted by haightjr View Post
I have a 95 ZJ 5.2l with the NP249 with a bad VC and performing the swap. I think I found my new NP242 out of a 92 XJ. Will I have any issues? Will the Input shaft from the NP249 fit? Thanks!
The only issue I think I might have after going through all the information for these swaps is the new and old style gear on the input shaft if I try to swap them. If thats the case, where could I find an input shaft that will work on the NP242? I will need to rebuild the transfer case anyways so i would rather get a new input shaft for it and i could maybe keep the 249 as a backup if needed.
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Unread 02-19-2013, 06:28 PM   #1523
Andrewm6097
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I picked up a 242 out of a 98 grand cherokee. I'm replacing the seals but I'm having trouble finding the correct rear output seal. In the picture, left is the original, middle is national brand part #4370n, on the right is timken brand part #4370n. What gives? They're all different and both the new ones have too small of a diameter to even fit. Anyone else have this problem? Where should i get the correct part?

forumrunner_20130219_202241.jpg
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Unread 02-19-2013, 06:43 PM   #1524
zarnold
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Try Novak: http://www.novak-adapt.com/knowledge/np242.htm

This is a better link: http://www.novak-adapt.com/catalog/t..._242_parts.htm
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Unread 02-20-2013, 12:41 PM   #1525
ghatid
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What do you guys end up doing with your old 249s?
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Unread 02-20-2013, 02:43 PM   #1526
zarnold
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Originally Posted by ghatid
What do you guys end up doing with your old 249s?
Mine is taking up space in my garage. Don't know what will happen to it.
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Unread 02-20-2013, 03:36 PM   #1527
mandrews000
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Originally Posted by ghatid View Post
What do you guys end up doing with your old 249s?
Mine is holding my old cat converter down in my driveway...
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Unread 02-20-2013, 05:37 PM   #1528
zarnold
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Quote:
Originally Posted by Andrewm6097 View Post
I picked up a 242 out of a 98 grand cherokee. I'm replacing the seals but I'm having trouble finding the correct rear output seal. In the picture, left is the original, middle is national brand part #4370n, on the right is timken brand part #4370n. What gives? They're all different and both the new ones have too small of a diameter to even fit. Anyone else have this problem? Where should i get the correct part?
So, any luck on the seal? It seems like everything I see is a kit, which is fine if you need the whole kit.

Another option is to straiten out your old seal and reuse it. That's what I ended up doing.
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Unread 02-20-2013, 06:36 PM   #1529
Andrewm6097
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I found the correct one at napa today. It was 18 bucks though... I'll try to remember to post the part number tomorrow. The part number that's listed in this thread is wrong, in my case anyway....
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Unread 02-21-2013, 04:23 PM   #1530
Mark-318-IT
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hi guys now i have a 98 limited 318 with the 249 but the vc is going bad...so i'd like to swap a 242.

i have a big doubt with the 242: can i use 4wd full-time at any speed? like the 249? or do i have some limits?
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