Transfer Case Swap Info NP249->NP231 & NP242 - Page 13 - JeepForum.com
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Unread 11-04-2010, 10:41 AM   #181
PlatinumNiner
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1998 ZJ 
 
Join Date: Oct 2009
Location: Long Island NY
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I dont think so. I believe the driveshaft or yoke length is different. I think 93-95 is different from 96-98

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Unread 11-04-2010, 03:12 PM   #182
tonyp6796
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1996 ZJ 
 
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Quote:
Originally Posted by lonecountryboy View Post
I just did my 249 to 231 swap and it was a direct swap, no problems on the linkage. Did you use the tab off the 231? If you didn't you need to otherwise it will be to long. I even got the VIC to work with the 231, I was going to do a write up on it but nobody seemed interested so I didn't worry about it. Oh I also have a 96, what year was your 231 out of? Mine was out of a 96 xj so the year that you got your donor out of will make a difference.
my 231 is out of a 93 zj and its going into my 96 zj which had the 249 in it. it all hooks up but when its put into 2wd the linkage bars hits the middle pivot bar not letting it go all the way into gear. Im not sure if i need to shorten, lengthen, or maybe even put a bend in the linkage.
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Unread 11-07-2010, 04:49 PM   #183
lonecountryboy
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Sounds like your going to need to shorten it. Most of the time it is to long and will do what you are describing. Unhook it and put your selector in 2wd and measure center to center to get the correct length and then if you know a welder or fabricator have them modify it for you. You could try the junkyards and see if you could find one a different length but I don't think you will.
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Unread 11-12-2010, 04:13 PM   #184
V852
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1994 ZJ 
 
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Quote:
Originally Posted by PlatinumNiner View Post
I dont think so. I believe the driveshaft or yoke length is different. I think 93-95 is different from 96-98
Thanks.

Any idea, what about a 242er from an 91er XJ? May it fit?
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Unread 11-12-2010, 06:47 PM   #185
PlatinumNiner
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Not 100% sure i believe in 91 the spline count changed so that should match up on your 94. Im not to up on the 93-95 ZJ
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Unread 11-13-2010, 12:40 PM   #186
OrangePower
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1997 ZJ 
 
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I have 242 out of 91 xj and my zj is 97. I know about different cut, option to swap only back end….
My question is if anybody replaced rear AT transmission seal for thicker one?
Difference you can measure on 249 transfer case input shaft and on 242 transfer shaft (mark that seal left on input shaft) is only 3mm, so we only need 3mm thicker AT transmission rear seal.

What do you think?
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Unread 11-21-2010, 08:04 PM   #187
Oli
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1994 ZJ 
 
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Hello,

I just completed the swap for a np242. The np242 was out of a 92 xj, and my np249 was a post 94.5 with the internal slip yoke, so I did keep the front half of the np249 and it input gear and used all others parts from the np242.

Everything went quite well and I didnt had unpleasant surprises, but I do have some questions :

On the np249, the 4wd switch is on the front part, and it engages only when the shift sector is in low. On the np242, the 4wd switch is on the back part, and it selection depends of the shift rail position. I did reconnect the 4wd switch of the np249 front half, because the connectors where not the same. With my sepup, is it right to say than even if I switch the plugs behind the vic, it will never display the "part time", "full time", and wheels powered? Can I use the np249 switch in the np242, even if it doesnt have the same connector?

Secondly, (and this is my main concern): I did used the speedometer assembly from the np249... I guess this was not right because now my speed gauge is not working at all and my transmission is not shifting. Please tell me than the transmission is activated by this reading of the speed and that I did not ruined it... Here again, I did used the speedometer assembly of the np249 because the connectors where not the same. Can I use the pinion gear and the adapter of the np242 with the speed sensor of the np249? if not, what are my options?

Finally, I did test drive it at low speed and I would like to know if this is normal to get some "binding" with this transfer case? It did hop a bit when doing prononced turns...

Thanks again for the help !

EDIT : Ok, after some more research, I probably didnt rotate the speed sensor corectly to engage the gears together. I also read than this is normal to get binding with the np242 on 4wd part time and 4wd low, and that theses options should never be used on pavement. My first question is the only one remaining, can I use the np249 4 prong plug 4wd switch in the hole of the np242 (reaching the shift rail)?

Thank you.

Last edited by Oli; 11-23-2010 at 07:50 PM..
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Unread 11-26-2010, 10:30 AM   #188
Mike97ZJ
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Great post Jr!! All the pics and info are really helpful.

I hate to post aother question, but I just want to make sure my facts are straight.

I have a 97 4.0 with a ISY 249. I just picked up a 242 from a 99 XJ, the build date on the case is 10/98. From what I understand the spline count should be the same, correct?

One twist...I wasn't thinking about it when I picked it up (only 75 bucks) but it turns out it's a ESY case.

So from what I understand the external slip yoke is 1.5" longer than the internal that I have now, so my rear DS won't work.

Do I need to have a DS from a ESY 242 ZJ, or will one from an XJ work? The XJ style seems to be much easier to find,I see alot of them being parted out on CL locally.

Also, the 242 I have now doesn't have the linkage, just the shift arm on the case. My 249 linkage should bolt up and work okay, corect?

Thanks alot for any info, I reallyappreciate it.
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Unread 11-26-2010, 07:21 PM   #189
comptiger5000
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Your rear DS may work, or it may not. If it's too long, A DS off a 96-98 4.0 ZJ with a 242 (will be ESY in those years) will work. If you can't find one of those, a rear DS off a 96-98 5.2 ZJ (d44a rear) should fit as well, and be a bit shorter than your current one. Other than that, the case will bolt right up.

As far as linkage, the 249 linkage will work fine hooked up to the 242 shift arm on the case.
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Unread 11-26-2010, 09:31 PM   #190
fsubrian195
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1995 ZJ 
 
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ok how much work to swap a np242j with a build date of 11/15/96 and esy into my np249j's spot with a build date of 08/11/94 and isy? its a 95 zj with the 5.2
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Unread 11-26-2010, 10:54 PM   #191
JrMechanic
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Quote:
Originally Posted by fsubrian195 View Post
ok how much work to swap a np242j with a build date of 11/15/96 and esy into my np249j's spot with a build date of 08/11/94 and isy? its a 95 zj with the 5.2
You will need to use the 249 front half, and have your drive shaft cut and balanced.
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Want to swap an NP242 or NP231 into your ZJ? Here's how:
http://www.jeepforum.com/forum/f13/n...pdated-685644/
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Unread 11-27-2010, 09:06 AM   #192
fsubrian195
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so i would have to swap the input and pretty much have a new drive shaft made?
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Unread 11-27-2010, 09:15 AM   #193
Mike97ZJ
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Quote:
Originally Posted by comptiger5000 View Post
Your rear DS may work, or it may not. If it's too long, A DS off a 96-98 4.0 ZJ with a 242 (will be ESY in those years) will work. If you can't find one of those, a rear DS off a 96-98 5.2 ZJ (d44a rear) should fit as well, and be a bit shorter than your current one. Other than that, the case will bolt right up.

As far as linkage, the 249 linkage will work fine hooked up to the 242 shift arm on the case.
Thanks for the tip on the DS!!
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Unread 11-27-2010, 10:42 AM   #194
JrMechanic
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Quote:
Originally Posted by fsubrian195 View Post
so i would have to swap the input and pretty much have a new drive shaft made?
Yes, you would have to swap the input. Please excuse what I said before about the front case, with a build date of 8/94 you should have the newer gear cut, however this is pretty close to the change over and could be either.

I wouldn't do this swap without a SYE though if you plan to lift it anymore than 3.5". The rear drive shaft in 93-95 V8 ZJ's is already pretty short. By making it shorter you're just asking for drive line vibes.
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Want to swap an NP242 or NP231 into your ZJ? Here's how:
http://www.jeepforum.com/forum/f13/n...pdated-685644/
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Unread 11-27-2010, 08:51 PM   #195
anderob
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Sorry for adding to this post with more questions.
I have read through this twice and I just want to make sure that I have everything I will need for this swap. I will be doing the swap in a friends shop and will only be able to use the lift for a few hours.

I just bought a 1997 ZJ Limited with 140,000 on the clock. It has the 4.0 and I think the trans is a 42RE but I am not sure. The TC is a 249 Quadratrac. I am pretty sure that the diff is the Chrysler 8.25 since it has the rubber plug in the cover. The ZJ drives but when you make close turns the front tires skip a lot. So I am sure that the TC is ready to go south.

I have two XJ AW4 transmissions with NP231s bolted to them. One is from a 96 with the 4.0 and the other is from a 98 with the 4.0.

First I need to confirm that the transmission is a 42RE so I can get a rear seal for it. I don't see any tags on it.
So will the VIN # tell me?

Please correct me if I am wrong.

From what I have gathered the 231 will bolt up and work with no internal mods. I do have all of the shifter brackets from the XJs so I should have what I need to operate the shifter.

The drive shaft from the 249 is the internal slip one. The shafts from the 231s have the external slip ones.

So in order to have everything ready, I will need a rear trans seal, the correct drive shaft, and one of the 231s and shift linkage that I already have.

How do I identify my transmission? I do not see any tags on it.

Can I find a driveshaft from a ZJ that will work with my swap? If so, when I hit up the salvage yard next week what years, motor, trans, TC case, diff will I want one from.
I do have the original XJ shafts. I am not too sure if one of those will work though.

Am I going to have to switch anything so the speedo and VIC works correctly?
I believe the red wires will have to be unplugged and I will need to find the black ones and plug them in for the VIC.

Is there anything else that I am missing or will need?

By the way great post JrMechanic!!!!!
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