Transfer Case Swap Info NP249->NP231 & NP242 - Page 115 - JeepForum.com
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Unread 09-30-2013, 10:47 AM   #1711
Jeeples
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Did my swap this past Saturday. Everything went great and I replaced both the T-Case input seal and the trans output seal (which was leaking considerably). However I think I may have gotten a bad T-case. When I bought it from the junkyard I checked to make sure the shifter tab moved through each position and that the in and outputs moved like they were supposed to.

The issue I am having is that I am getting a rattling/grinding sound coming from the case, even when in 2WD. The worst noises come when I have the trans and t-case in neutral and then shift into 4WD part time then put the trans in drive.

I think my issue is with the linkage, as I only used the shifter base from the donor vehicle. I tried adjusting it, but it looks like the arm that attaches directly to the t-case shift tab is too long and hitting the case. I picked up a 242 linkage and will toss that in tonight and see where I stand then. Hopefully my issue is just not fully shifting into each gear.

Any other ideas?

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Unread 09-30-2013, 01:44 PM   #1712
zarnold
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Quote:
Originally Posted by Jeeples
Did my swap this past Saturday. Everything went great and I replaced both the T-Case input seal and the trans output seal (which was leaking considerably). However I think I may have gotten a bad T-case. When I bought it from the junkyard I checked to make sure the shifter tab moved through each position and that the in and outputs moved like they were supposed to.

The issue I am having is that I am getting a rattling/grinding sound coming from the case, even when in 2WD. The worst noises come when I have the trans and t-case in neutral and then shift into 4WD part time then put the trans in drive.

I think my issue is with the linkage, as I only used the shifter base from the donor vehicle. I tried adjusting it, but it looks like the arm that attaches directly to the t-case shift tab is too long and hitting the case. I picked up a 242 linkage and will toss that in tonight and see where I stand then. Hopefully my issue is just not fully shifting into each gear.

Any other ideas?
Seeing how your changing the linkage, I would put it in 2wd manually, then test it.
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Unread 09-30-2013, 02:19 PM   #1713
Jeeples
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I did try that on Saturday and even in what I think is 2WD (shift tab all the way towards the front of the vehicle) I still got like a rattling noise from the case. Again I'm not certain that I had the T-case full engaged into 2WD. Swapping out the linkage is pretty quick so I'll try that after work and see what happens.

I guess the question I really need to ask is if it's common for 242's to make that kind of noise and/or what could be the cause?
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Unread 09-30-2013, 04:51 PM   #1714
zarnold
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Yeah, 2WD is all the way forward. If you have it in gear, it not should be making any noise. There are several videos online with stretched chain sound. That's one thing that it might be, hopefully it's linkage.
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Unread 09-30-2013, 06:47 PM   #1715
Jeeples
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Well the new linkage helped but I'm still getting the noise and it feels like I'm in 4WD when making sharp turns as it binds the wheels up.

I think the case is toast.
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Unread 09-30-2013, 07:25 PM   #1716
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Sounds like it. Does your JY give a warranty?
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Unread 09-30-2013, 07:50 PM   #1717
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Yeah its 90 days. Luckily they had several 242's there to choose from.

Is there an inspection hole to check the chain or should I just split the case at the yard?
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Unread 10-01-2013, 07:02 AM   #1718
zarnold
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Nope, no way to inspect the chain without cracking the case.

I would:
Drain it and inspect the fluid.
Make sure it will go into all modes e.g. 2WD, 4PT, 4FT....
Spin the outputs in all modes.
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Unread 10-01-2013, 08:17 AM   #1719
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Originally Posted by zarnold View Post
Nope, no way to inspect the chain without cracking the case.

I would:
Drain it and inspect the fluid.
Make sure it will go into all modes e.g. 2WD, 4PT, 4FT....
Spin the outputs in all modes.
Yep, that's pretty much what I did with this case. Maybe I'll make sure the case is flat on the ground and spin it fast enough to see if I can hear the chain dragging on the case.
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Unread 10-02-2013, 06:04 AM   #1720
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Originally Posted by Jeeples View Post
Yep, that's pretty much what I did with this case. Maybe I'll make sure the case is flat on the ground and spin it fast enough to see if I can hear the chain dragging on the case.

Grab the front output, and turn it in one direction then the other rather quickly.. a signifigantly stretched chain can be heard to slap the outer case half.
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Unread 10-02-2013, 04:55 PM   #1721
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So ive been following this thread for a while now and I think I can tackle this. The only concern I have is the gear cut change. I have a '95 zj with a '95 249. My donor 231 is a '94. The gear change im told is mid 94-95 for a 249. Does this apply to the 231 as well? Or does the gear cut remain consistant. Is there any place you can find EXACTLY what you have based on tc serial numbers?
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Unread 10-03-2013, 06:45 AM   #1722
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Originally Posted by scheercat View Post
So ive been following this thread for a while now and I think I can tackle this. The only concern I have is the gear cut change. I have a '95 zj with a '95 249. My donor 231 is a '94. The gear change im told is mid 94-95 for a 249. Does this apply to the 231 as well? Or does the gear cut remain consistant. Is there any place you can find EXACTLY what you have based on tc serial numbers?
So, what is the length of your input shaft? Here is a chart from the initial post:

93-95 V8 ZJ's: 46RH transmission, 1.55" 23 spline input shaft
93-95 I6 ZJ's with the 42RE: .840" 23 spline input (with collar)
93 I6 ZJ's with the AW4 or AX15: .750" 23 spline input
All 96-98 ZJ's: .840" 23 spline input
All 96-01 XJ's: .840" 23 spline input
92-95 XJ's: .750" 23 spline input
91 and older XJ's: .750" 21 spline input

And, what is the length of the 231's input shaft? You may not have to swap the inputs.

The gear cut change affected all models.
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Unread 10-03-2013, 09:35 AM   #1723
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Quote:
Originally Posted by scheercat View Post
So ive been following this thread for a while now and I think I can tackle this. The only concern I have is the gear cut change. I have a '95 zj with a '95 249. My donor 231 is a '94. The gear change im told is mid 94-95 for a 249. Does this apply to the 231 as well? Or does the gear cut remain consistant. Is there any place you can find EXACTLY what you have based on tc serial numbers?
Have you pulled your 249 out yet? I believe that is the only way to know your gear cut for sure. Check and see when your 95 was actually manufactured.

My 95 was made in oct of 94, i pull

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Unread 10-03-2013, 09:36 AM   #1724
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Quote:
Originally Posted by scheercat View Post
So ive been following this thread for a while now and I think I can tackle this. The only concern I have is the gear cut change. I have a '95 zj with a '95 249. My donor 231 is a '94. The gear change im told is mid 94-95 for a 249. Does this apply to the 231 as well? Or does the gear cut remain consistant. Is there any place you can find EXACTLY what you have based on tc serial numbers?
Have you pulled your 249 out yet? I believe that is the only way to know your gear cut for sure. Check and see when your 95 was actually manufactured.

My 95 was made in oct of 94, i pulled it apart and found i had the later gear cut. So i bought a 2000 231. So yeah, you'll just have to pull it apart and compare.

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Unread 10-03-2013, 01:37 PM   #1725
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The VIC in the '95 correctly displayed for the NP231 when they were both factory installed by Chrysler, and it displayed correctly up until two weeks ago when I pulled the case out.

I recognize that the '96-'98 VIC is probably actually a different part number, which may prohibit the '95 NP231 from displaying correctly. (I haven't ripped into the '98 dash yet; I need to swap a stereo, run wires for the VHF, and solder the back of the VIC for the "coolant temp switch" warning, as well as the back of the headlight switch for the auto-headlight-flickering issue. Those are all scheduled for this weekend.)

But what about the VIC in the '95? What do I need to do to make it recognize the NP249? Right now all four tires light up with the RED plug connected, but only when in neutral. When the NP249 is in either high or low range, all four tires go blank.
FWIW, I got the plugs swapped behind the '98 (red disconnected, black is now connected). With the NP231 from the '95 installed into the '98, the VIC displays 2WD correctly; in 4-high, all four tires light up and it displays "part time;" all four tires go away when in neutral; in 4-low, all four tires light up and it displays "part time," but not "lo." My '98 FSM just arrived in the mail two days ago, and it specifically states that this is the correct set of displays for a '98 with an NP231. (I didn't know the NP231 was even an option in any ZJ in '98, so I wonder if that information is just a carry-over from earlier FSMs. Either way, I'm happy.)

I gave up on making the '95 VIC display correctly with the '98 NP249. With the red plug connected and the black plug disconnected in the '95, it remains with all four tires blank when in both high and low range, and all four tires light up in neutral. It doesn't indicate full-time/part-time/lo or anything else. I went through a variety of different connection possibilities between the black and red wires using scrap wire as jumpers and never found a solution.
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