Transfer Case Swap Info NP249->NP231 & NP242 - Page 123 - JeepForum.com
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Unread 11-26-2013, 07:01 AM   #1831
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.


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Unread 11-26-2013, 08:09 AM   #1832
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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Unread 11-26-2013, 06:02 PM   #1833
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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Unread 11-26-2013, 06:22 PM   #1834
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.
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Unread 11-26-2013, 06:58 PM   #1835
Platinum5nine
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Look at posts 1795 and 1796
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Unread 11-27-2013, 03:56 AM   #1836
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.
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Unread 11-27-2013, 08:32 AM   #1837
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".
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Unread 11-28-2013, 02:15 AM   #1838
hondakilla98
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The transmission length might have something to do with it.
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Unread 11-28-2013, 11:12 AM   #1839
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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Unread 11-30-2013, 01:34 PM   #1840
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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Unread 11-30-2013, 01:56 PM   #1841
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?
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Unread 11-30-2013, 03:34 PM   #1842
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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Unread 11-30-2013, 03:41 PM   #1843
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.
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Unread 11-30-2013, 03:53 PM   #1844
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.
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Unread 11-30-2013, 04:04 PM   #1845
mrgimble
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I'll just get the DS shortened at a shop.
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