Transfer Case Swap Info NP249->NP231 & NP242 - Page 111 - JeepForum.com
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Unread 08-26-2013, 11:47 PM   #1651
95chameleonzj
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Quote:
Originally Posted by dnuccio View Post
you'll need to swap inputs
Alright what year would I need to get to not have to swap? Or do I have to no matter what


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Unread 08-27-2013, 04:18 AM   #1652
RagTagSoldier
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Quote:
Originally Posted by zarnold

Mechanical speedometer pickup, but I'm sure it was included. Your going to need the short tab too. Somebody on this forum drilled holes in the long 249 tab and was successful in getting it to work.
Ic well I will do some looking around maybe I'll get lucky and find the post. Thank you!

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Unread 08-27-2013, 08:37 AM   #1653
StridAst
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Quote:
Originally Posted by 95chameleonzj View Post

Alright what year would I need to get to not have to swap? Or do I have to no matter what

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You will have to swap no matter what. Well unless you get a drop in rebuilt one from transfer cases unlimited. (Www.transfercase.com) ~$830 if I remember correctly.
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Unread 08-27-2013, 06:08 PM   #1654
JrMechanic
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Quote:
Originally Posted by StridAst View Post

You will have to swap no matter what. Well unless you get a drop in rebuilt one from transfer cases unlimited. (Www.transfercase.com) ~$830 if I remember correctly.
Or transfer case solutions...
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Unread 08-27-2013, 08:21 PM   #1655
OverlandZJ
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Quote:
Originally Posted by 95chameleonzj View Post
So quick question here I have a 95 with the np 249 and I went to the jy and found two transfer cases one 231 and one 242 both rigs are pre 95 one is a zj and one is a xj. Would it just be a direct swap for either one? And what one do you recommend?

I'd grab the 242. In the event it's not the correct length input you could use the 249's front case half guaranteeing a compatible transfer. Just need to drill one hole and swap parts.

I just did such, had a rebuilt XJ 242 w/SYE I wanted to put in my new build.
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Unread 08-29-2013, 04:04 PM   #1656
Myusername1674
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Hey all you t-case guys, gotta question. I broke down my 249 today to find out what gear cut my jeep is. My Jeep was born 10-94. So I'm pretty sure it's the later gear cut. Can anyone tell me based on the pictures I've got if this is the new gear cut or the old gear cut?





Do I need to break the out shaft down further to be able to determine? If so let me know and I'll go do it tonight.


Also I found a guy within a few hours of me with an np231 from a 2000 xj. He said he'll sell it for $100 so I'm very tempted to get it. if I do have the new gear cut then I shouldn't have any problems swapping this in right? Any helps great. thanks
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Unread 08-30-2013, 06:34 AM   #1657
dave_dj1
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I'm no expert but if you compare it to the pics on THE FIRST PAGE, it looks to be the newer style.
You do not have to tear it apart any further.
good luck.
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Unread 08-30-2013, 06:55 AM   #1658
Myusername1674
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Originally Posted by dave_dj1 View Post
I'm no expert but if you compare it to the pics on THE FIRST PAGE, it looks to be the newer style.
You do not have to tear it apart any further.
good luck.
Yeah i believe your right, i pulled it apart more to look at it, and i compared it to pics on a different site. Sweet, now i jus gotta go get a case

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Unread 09-04-2013, 12:50 AM   #1659
Owens13
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Hey there. I am wanting to swap out my tired 249 for a 231. Especially since the VC is taking a southern dive really fast with daily driving and 198k on the clock. After reading several pages in here I have came to the conclusion that since my ZJ is a 1996 with a 5.2, that it has 23 spline .840" input with an Internal slip yoke. I am sure the answer has already been mentioned but after hours of reading i am still not sure what would be the best option to swap out. I see that a 93-95 has the same input spline and measurement but has the collar and have to split the cases to swap inputs anyways. Could someone please tell me if there is a direct, no swapping parts, bolt in fit for my application? Im not against a little work but it would be nice to find a case that is a direct fit if possible. Any help with this would greatly appreciated. Again sorry if this has already been answered but i would like a direct answer so I dont waste time with cases that wont work or ones that are not a good idea. Thanks
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Unread 09-04-2013, 07:17 AM   #1660
Maine1994ZJ
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I'm pretty sure you'll have to do an input shaft swap, regardless.
From what I gather, the V8s all had the 1.5" shaft, and no 231's came with a shaft longer than .840".
I may be off on this, but that's what I recall from the many pages here.
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Unread 09-04-2013, 07:49 AM   #1661
dave_dj1
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Get yourself a nice clean work bench and have at it. The nice thing is you don't have to put your 249 back together!
When shopping for a good set of snap ring pliers, (I got mine at Sears), you don't want the kind with the two points. The kind I use for these particular snap rings are flat on the ends and work great! A set of ones with the points is handy for one snap ring, the rest use the flat ones.

I don't see my exact ones but these are similar
http://www.sears.com/kd-tools-snap-r...blockType=G118

The rings themselves are called E-rings, no holes.
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Unread 09-04-2013, 08:59 AM   #1662
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Quote:
Originally Posted by Maine1994ZJ View Post
I'm pretty sure you'll have to do an input shaft swap, regardless.
From what I gather, the V8s all had the 1.5" shaft, and no 231's came with a shaft longer than .840".
I may be off on this, but that's what I recall from the many pages here.
Only 93 - 95 V8s had the 1.5" shaft. All 96+ ZJs, regardless of engine, have a .840" shaft.
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Unread 09-04-2013, 09:11 AM   #1663
zarnold
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Quote:
Originally Posted by Owens13 View Post
Could someone please tell me if there is a direct, no swapping parts, bolt in fit for my application? Im not against a little work but it would be nice to find a case that is a direct fit if possible. Any help with this would greatly appreciated. Again sorry if this has already been answered but i would like a direct answer so I dont waste time with cases that wont work or ones that are not a good idea. Thanks
Are you going to lock your front axle? If not the easiest and most direct way is to fix your 249. The 242, 231 are both great cases, and will bolt right in, but
you’re most probably going to have to shorten your driveshaft, unless your jeep is lifted. If you’re lifted 3.5" or more you may not have to shorten the driveshaft.
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Unread 09-04-2013, 05:52 PM   #1664
Maine1994ZJ
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Quote:
Originally Posted by comptiger5000 View Post
Only 93 - 95 V8s had the 1.5" shaft. All 96+ ZJs, regardless of engine, have a .840" shaft.
Thanks for clarifying! Musta missed that tidbit....
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Unread 09-05-2013, 03:27 AM   #1665
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Quote:
Originally Posted by zarnold View Post
Are you going to lock your front axle? If not the easiest and most direct way is to fix your 249. The 242, 231 are both great cases, and will bolt right in, but
you’re most probably going to have to shorten your driveshaft, unless your jeep is lifted. If you’re lifted 3.5" or more you may not have to shorten the driveshaft.
If you're on stock control arms, the lift your ZJ might have has very little to do with not having to cut your driveshaft. In fact, on stock arms, you might have to cut it even more if you're lifted. Think about how the axle moves when it droops. The rear of the ZJ is a 4 link radius design. As the axle comes down, it moves more toward the center of the vehicle. What happens to the driveshaft at this point? It moves farther onto the slip yoke on the transfer case to "shorten" the length. As the axle moves closer to the body, like when you hit a speed bump, the axle moves away from the center of the vehicle. This causes the driveshaft to move farther off the slip yoke to "lengthen" it. With leaf sprung vehicles, it's the opposite and lift would make a difference.
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