Transfer Case Swap Info NP249->NP231 & NP242 - Page 112 - JeepForum.com
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Unread 09-06-2013, 10:46 AM   #1666
Owens13
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Yes my ZJ is lifted. It has the 3.5 " Skyjacker kit on it with their lower control arms. I really want to stick to a 231 to swap and no I do not intend to lock the front axle. But who knows what the future holds. switching inputs wouldn't be a bad thing. Just didn't know if there was a 231 from a specific year and whether it be an XJ or ZJ that would be a direct replacement. Looks like I'll be doing a little bit of case splitting.

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Unread 09-06-2013, 11:28 AM   #1667
zarnold
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Quote:
Originally Posted by Owens13
Yes my ZJ is lifted. It has the 3.5 " Skyjacker kit on it with their lower control arms. I really want to stick to a 231 to swap and no I do not intend to lock the front axle. But who knows what the future holds. switching inputs wouldn't be a bad thing. Just didn't know if there was a 231 from a specific year and whether it be an XJ or ZJ that would be a direct replacement. Looks like I'll be doing a little bit of case splitting.
You want a 96 - 01 XJ, or a 96 - 98 ZJ. If you can find a 231 in one of these you should be good.
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Unread 09-09-2013, 11:33 PM   #1668
Owens13
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Thanks for the info guys.
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Unread 09-11-2013, 02:27 AM   #1669
SaviorSelf
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Hey fellas'

Got my tired old 249 out of my 94 GC 4.0 Limited (42RE)

Bought all new seals.

'Old' 249: Build date Apr 8, 1994 (ZJ)

'New' 242: Build date Sept 11, 1996 (XJ)

Clean one is the 242.







Next step is to do a 'front case swap'. Right?
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Unread 09-11-2013, 07:35 AM   #1670
comptiger5000
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Measure the inputs first. If they're already the same length, then you're good to go as-is.
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Unread 09-11-2013, 08:01 AM   #1671
zarnold
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Quote:
Originally Posted by comptiger5000
Measure the inputs first. If they're already the same length, then you're good to go as-is.
^ this

Looks like the input on the 249 is longer, but it's hard to tell from the pics.

It should be the same:

93-95 I6 ZJ's with the 42RE: .840" 23 spline input (with collar)
All 96-01 XJ's: .840" 23 spline input
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Unread 09-11-2013, 01:03 PM   #1672
SaviorSelf
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From what it looks like it is a 23 spline but the 242 I got has a .750 spline and my 249 obviously has the 23 spline but .840 spline.
So technically this should be a direct swap? Just gotta make sure to RTV the TC to the Tranny real good. Since the shaft is a little smaller.

i'll assume the PO swapped the inputs for some unknown reason.

Here's some pics for reference for the future.

242:


249:
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Unread 09-12-2013, 01:16 AM   #1673
SaviorSelf
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Well I went ahead and finished the swap with the short input. I RTV'd the tranny to the TC just incase but from the looks of when I was sliding the TC in, the shaft made it into the seal pretty far. No leaks after a test run. Going to have to adjust my linkage but all in all pretty smooth swap!
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Unread 09-12-2013, 07:51 PM   #1674
Myusername1674
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Random question, anyone know the trick to get the tailcone off an external slip yoke np231?? I'm at a loss as to how to access the snap ring. (im assuming there is one)



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Unread 09-12-2013, 08:30 PM   #1675
zarnold
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Quote:
Originally Posted by Myusername1674
Random question, anyone know the trick to get the tailcone off an external slip yoke np231?? I'm at a loss as to how to access the snap ring. (im assuming there is one)

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Oil slinger has to be removed, then the snap ring.
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Unread 09-12-2013, 09:09 PM   #1676
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Quote:
Originally Posted by zarnold View Post

Oil slinger has to be removed, then the snap ring.
Gotcha. How should i go about removing this thing?? I've tried hammering with no luck. It's pretty stuck

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Unread 09-12-2013, 10:02 PM   #1677
zarnold
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Quote:
Originally Posted by Myusername1674 View Post
Gotcha. How should i go about removing this thing?? I've tried hammering with no luck. It's pretty stuck

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A puller may work, but it didn't for me (just bent the slinger up). What I ended up doing was cutting a very slight indentation onto the slinger with a cold chisel . Once I had a notch, I could turn the chisel just a little sideways and get the slinger to turn on the shaft (still using a hammer of course). Once it starts to move it goes pretty quickly. Be very careful not to cut all the way thru your slinger and damage the shaft.
oil_slinger.jpg  
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Unread 09-13-2013, 07:21 AM   #1678
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Quote:
Originally Posted by zarnold View Post
A puller may work, but it didn't for me (just bent the slinger up). What I ended up doing was cutting a very slight indentation onto the slinger with a cold chisel . Once I had a notch, I could turn the chisel just a little sideways and get the slinger to turn on the shaft (still using a hammer of course). Once it starts to move it goes pretty quickly. Be very careful not to cut all the way thru your slinger and damage the shaft.
Okay sweet! That's probably what I'll do. I'll try it when I get home from school.

Edit: Worked great, thanks man!
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Unread 09-16-2013, 05:25 AM   #1679
tweb
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Ok my head is spinning, I have a 95 gc 4.0 with a 249tc production date of 10/27/93. So my question is what year 231 or 242 should I be looking for to do a swap?
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Unread 09-16-2013, 08:06 AM   #1680
Myusername1674
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Quote:
Originally Posted by tweb View Post
Ok my head is spinning, I have a 95 gc 4.0 with a 249tc production date of 10/27/93. So my question is what year 231 or 242 should I be looking for to do a swap?
I'm pretty new to the whole transfer case swap so don't quote me on this, but here's what I think I've learned correctly from researching and reading.


Your Jeep 249 case has a 23 spline input shaft with the old style gear cut. You need to find another jeep that was made between 92 and 94.

You want 92+ because Jeeps changed from 21 to 23 spline input the year before.

You want 94- because After 94 Jeep changed to a different gear cut on the input.

You could take one from a 95 but if it was a late production model 95 it will most likely have the new style gear cut. (My 95 zj was made 10-94, and it has the new style gear cut.)

So basically look for one out of a 92-94 Jeep. You should be able to swap shafts and go on being happy. But remember, I'm no expert, so make sure to research what I've said more before buying a case.
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Want your zj to be doorless in 60 seconds?
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