Transfer Case Swap Info NP249->NP231 & NP242 - Page 123 - JeepForum.com

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post #1831 of 3149 Old 11-26-2013, 07:01 AM
dr hook
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I swapped the ol 249 in my 96 for a 231 a couple of weeks ago. I had 3 jeep front driveshafts laying around, and all of them were roughly 2.5" too long. I finally got to the junk yard yesterday. Found a ZJ with the 4.0/242 combo, and snatched the front shaft out... only to get home and discover that it is also 2.5" too long. I cussed. Any suggestions on what a specific year/combo i can get a front shaft from?

My ZJ is a 96 5.2 limited. It originally had the 249 with the rezeppa front shaft. It now has a 231 and I need a u-joint front shaft.



Lifted ZJ with stuff.
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post #1832 of 3149 Old 11-26-2013, 08:09 AM
zarnold
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Quote:
Originally Posted by dr hook View Post
I swapped the ol 249 in my 96 for a 231 a couple of weeks ago. I had 3 jeep front driveshafts laying around, and all of them were roughly 2.5" too long. I finally got to the junk yard yesterday. Found a ZJ with the 4.0/242 combo, and snatched the front shaft out... only to get home and discover that it is also 2.5" too long. I cussed. Any suggestions on what a specific year/combo i can get a front shaft from?

My ZJ is a 96 5.2 limited. It originally had the 249 with the rezeppa front shaft. It now has a 231 and I need a u-joint front shaft.
so, what drive shaft are you replacing?

rezeppa - rezeppa

or

double cardan - rezeppa

Seems like the ds you just got should do the job. Mine compressed so I could get it in.
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post #1833 of 3149 Old 11-26-2013, 06:02 PM
Platinum5nine
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I did the 242 swap on my 97 5.2 and 98 5.9, no problem with front or rear shafts in either. Not sure what your issue is here. Are the shafts frozen and not compressing?

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post #1834 of 3149 Old 11-26-2013, 06:22 PM
ejschultz
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Not every Jeep is the same. Some people will have issues with their stock driveshaft, others won't. It comes down somewhat to luck of the draw. With my aftermarket rear arms, upper and lower, and 4" of lift, I had to take an inch off. You'd think that'd be more than enough to not have to cut it. It wasn't though. You sound like you got lucky both times you did the swap.

97 ZJ - 5.2L, 242, 4" IRO lift w/short arms & adj. TBs, JKS Discos/BPEs, DT3000s, Aussie'd 44A, sliders, bumpers, bunch o' skids, 31" Duratracs on 15x8s
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post #1835 of 3149 Old 11-26-2013, 06:58 PM
Platinum5nine
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Look at posts 1795 and 1796

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 #1836 of 3149 Old 11-27-2013, 03:56 AM
ejschultz
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That's cool. When I did mine, my driveshaft was very close to bottoming out. Since my ZJ gets wheeled, I needed to shorten the driveshaft. Some people cant even get their original driveshaft in without shortening it. You were lucky, twice.

97 ZJ - 5.2L, 242, 4" IRO lift w/short arms & adj. TBs, JKS Discos/BPEs, DT3000s, Aussie'd 44A, sliders, bumpers, bunch o' skids, 31" Duratracs on 15x8s
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post #1837 of 3149 Old 11-27-2013, 08:32 AM
dr hook
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I am replacing the rezeppa shaft with a double cardan shaft. I now have 4 different DC shafts, and fully compressed they are about 2" too long.

And I forgot to add that my zj is lifted 4.5".

Lifted ZJ with stuff.
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post #1838 of 3149 Old 11-28-2013, 02:15 AM
hondakilla98
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The transmission length might have something to do with it.

5.9 Limited, RE 4" lift, RE FTB, JK take offs w/ 255/75/17 BFG MT's, 1.25" wheel adapters, ARB Bumper, Superwinch LP10000, K&N intake, Flowmaster, custom JL & Focal stereo, 20% tint, KOR roof mount tire carrier, JCR sliders, cobra 75 wx st
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post #1839 of 3149 Old 11-28-2013, 11:12 AM
mrgimble
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Quote:
Originally Posted by dr hook View Post
I am replacing the rezeppa shaft with a double cardan shaft. I now have 4 different DC shafts, and fully compressed they are about 2" too long.

And I forgot to add that my zj is lifted 4.5".
Why not get one shortened?
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post #1840 of 3149 Old 11-30-2013, 01:34 PM
mrgimble
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Just did a NP242 swap from a 2000 XJ in to a 1997 5.2 to replace the NP249. Followed the how to and everything went great.

My rear DS is 1.5" too long, as expected.
Front shaft fit fine.
I used the mode switch and speedo gear housing from the 242.
Changed plug behind the VIC and now the proper mode is displayed.

Thanks for the how to. woohoo
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post #1841 of 3149 Old 11-30-2013, 01:56 PM
Platinum5nine
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Post pictures of the output shaft on the t-case with the stock driveshaft installed. Are you lifted at all? Wheel it 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 #1842 of 3149 Old 11-30-2013, 03:34 PM
mrgimble
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Quote:
Originally Posted by Platinum5nine View Post
Post pictures of the output shaft on the t-case with the stock driveshaft installed. Are you lifted at all? Wheel it at all?
The drive shaft yoke was tight against the transfer case and I could still not get the axle end on. Stock height.
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post #1843 of 3149 Old 11-30-2013, 03:41 PM
Platinum5nine
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One option you have is cutting the yoke on the driveshaft down. Slip it on to the transfer case all the way and see if it bottoms out on the splines. If it does, you can CAREFULLY put the neep in drive, wheels chocked, the output shaft on the transfer case will spin, you can cut 1" off that end also. Thats how guys cleanly cut the output shafts on the 242 when installing a hack and tap. Just food for thought, not the only way to do it, but it is the free way to do it.

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 #1844 of 3149 Old 11-30-2013, 03:53 PM
ejschultz
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I cut the slip yoke on my driveshaft to make it fit. Better than any custom shaft because all it cost me was one reciprocating saw bade and a little cutting oil. I've wheeled it a handful of times since with no bottoming out or dropping issues. I only took off about an inch though. I don't know if that extra half inch for you would cause issues.

97 ZJ - 5.2L, 242, 4" IRO lift w/short arms & adj. TBs, JKS Discos/BPEs, DT3000s, Aussie'd 44A, sliders, bumpers, bunch o' skids, 31" Duratracs on 15x8s
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post #1845 of 3149 Old 11-30-2013, 04:04 PM
mrgimble
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I'll just get the DS shortened at a shop.
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