Transfer Case Swap Info NP249->NP231 & NP242 - Page 120 - JeepForum.com

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post #1786 of 3301 Old 10-25-2013, 09:01 AM
comptiger5000
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Quote:
Originally Posted by Myusername1674 View Post
That's exactly how mine was, so yeah you should be fine with 1.5 inches.



Well it's because of all of the different variables.

93-95 had longer transmissions and all had the dana 35 rear.

96-98 5.2's had shorter transmissions, but longer rear axle pinion; the dana 44a.

96-98 4.0 had different transmission (I think shorter than 93-95) and had the dana 35 rear. So these had longer driveshaft then the 96-98 5.2s.

Then you've got the 98 5.9, which I think has a different transmssion even then the 96-98 5.2.

On top of that, depending what case you swap in will make a difference, after 96 (I believe) Jeep transfer cases starting coming with an external slip yoke, which was 1.5 inches longer than their internal slip yoke counterparts.

Then you have the fact that most guys on here have lifts on their jeeps, anywhere from 1" to 5", and in some cases even higher. So basically, there are just too many variables to be able to determine unless you just do the swap and find out for yourself.
Excluding early 93s with an AW4 or a 5 speed setup, all 4.0 ZJs use the same trans (42RE) regardless of early / late. It's the same length as a later 5.2 trans (early 5.2 trans is longer).

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post #1787 of 3301 Old 10-25-2013, 11:20 AM
OverlandZJ
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Quick question..

Installed a rebuilt 242 (249 front 1/2 with 88 242 SYE'd internals) in my 98 OEM equipped 242 ZJ. I used the same speed sensor and picked up a short shaft 39 tooth gear for my 4:56 and 33's. I lined up the raised dot with the tooth range (39-45) on outside of speed sensor housing.. speedo is non operational.

I'm assuming I need to clock the housing (rotating clockwise?) to engage the gear to drive on output shaft, however that will have the retaining fork sitting outside of the slots. Is this common.. and nothing to worry about? Hate to strip a new gear..

I should also mention that I have yet to install the new rear axle that's geared.. currently still have the OEM 3:55 D35. But that should only read off on the speedometer.. not be inop correct?
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post #1788 of 3301 Old 10-25-2013, 12:14 PM
OverlandZJ
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Originally Posted by OverlandZJ View Post
I should also mention that I have yet to install the new rear axle that's geared.. currently still have the OEM 3:55 D35. But that should only read off on the speedometer.. not be inop correct?

Disregard..

The above seems to have been my issue. I had to get up to ~10MPH or better before the speedo started reading..
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post #1789 of 3301 Old 10-25-2013, 05:13 PM
Platinum5nine
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Right but if you go with your theory my 5.9 swap shouldnt have worked at all. Transmission didnt change, rear axle didnt change, rear driveshaft didnt change, all that changed is the t-case which was out of a 96 and should have been 1.5" longer. Im stock ride height and didnt have to shorten the rear driveshaft at all.

Platinum 5.9 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts
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post #1790 of 3301 Old 10-26-2013, 01:08 PM
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Quote:
Originally Posted by comptiger5000 View Post

Excluding early 93s with an AW4 or a 5 speed setup, all 4.0 ZJs use the same trans (42RE) regardless of early / late. It's the same length as a later 5.2 trans (early 5.2 trans is longer).
Gotcha. I have zero experience with the 4.0. Only other zj friend of mine has the 5.2 but in a 98


Quote:
Originally Posted by Platinum5nine View Post
Right but if you go with your theory my 5.9 swap shouldnt have worked at all. Transmission didnt change, rear axle didnt change, rear driveshaft didnt change, all that changed is the t-case which was out of a 96 and should have been 1.5" longer. Im stock ride height and didnt have to shorten the rear driveshaft at all.
Hahaha who even knows then. I sure as hell don't!

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post #1791 of 3301 Old 10-26-2013, 02:45 PM
Platinum5nine
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4.0 is the 42
5.2 is the 44
5.9 is the 46

dont know if one is longer or shorter than the other though.

Platinum 5.9 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts
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post #1792 of 3301 Old 10-26-2013, 03:08 PM
Platinum5nine
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How do i resize a picture so the forum can handle the upload?

Platinum 5.9 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts
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post #1793 of 3301 Old 10-26-2013, 03:39 PM
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Quote:
Originally Posted by Platinum5nine View Post
How do i resize a picture so the forum can handle the upload?

I would suggest using photobucket.

Yeah I know there is a size difference in the 5.2 generation split idk about 5.9.

95 FiveTwo ZJ, DD, Lifted, Locked on 35s,
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post #1794 of 3301 Old 10-26-2013, 06:34 PM
comptiger5000
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Quote:
Originally Posted by Platinum5nine View Post
4.0 is the 42
5.2 is the 44
5.9 is the 46

dont know if one is longer or shorter than the other though.
Not quite. Early 5.2s are 46s. 46RH is longer than a 46RE (by about 9 inches, IIRC). 42/44 RE are the same length (not sure about length vs 46RE).
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post #1795 of 3301 Old 10-26-2013, 11:11 PM
Platinum5nine
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1997 ZJ 5.2 lifted 4.5" with a 242 out of a 1997 ZJ 4.0 Driveshaft at stock length with plenty of room to go with out any concerns of bottoming out.
Attached Thumbnails
5.2.JPG  

Platinum 5.9 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts
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post #1796 of 3301 Old 10-26-2013, 11:12 PM
Platinum5nine
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1998 ZJ 5.9 stock ride height with a 242 out of a 1996 ZJ 4.0 Stock length rear driveshaft, plenty of room for a daily streen driven ZJ
Attached Thumbnails
5.9.JPG  

Platinum 5.9 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts
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post #1797 of 3301 Old 10-27-2013, 12:47 AM
comptiger5000
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Quote:
Originally Posted by Platinum5nine View Post
1998 ZJ 5.9 stock ride height with a 242 out of a 1996 ZJ 4.0 Stock length rear driveshaft, plenty of room for a daily streen driven ZJ
That's about how much I've got and I've fully compressed the rear suspension, fully drooped it and wheeled the Jeep and never bottomed it out.
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post #1798 of 3301 Old 10-28-2013, 03:16 PM
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Would a 242 from '98 have an internal or external slip yoke? Just trying to plan swapping from a 249 to 242 and want to make sure I don't need anything but the transfer case from the JY.
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post #1799 of 3301 Old 10-28-2013, 05:09 PM
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Quote:
Originally Posted by smccloud View Post
Would a 242 from '98 have an internal or external slip yoke? Just trying to plan swapping from a 249 to 242 and want to make sure I don't need anything but the transfer case from the JY.
External.

I think it was late 95 when external slip yokes started being installed across the XJ/ZJ line.
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post #1800 of 3301 Old 10-28-2013, 05:22 PM
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Quote:
Originally Posted by OverlandZJ
External. I think it was late 95 when external slip yokes started being installed across the XJ/ZJ line.
My 249 is internal

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