Transfer Case Swap Info NP249->NP231 & NP242 - Page 15 - JeepForum.com

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post #211 of 3248 Old 12-07-2010, 09:15 PM
Tangfan
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93 ZJ I6 change out

Great thread, was very helpful. Some added information that I was unable to find. Swapped a 242 TC from a 96 ZJ with a 0.840" input shaft for oiginal 249 TC with a 0.750" input shaft in my 93 ZJ with a I6 engine. transmission had significant enough clearance so that added shaft length was no issue. Was not enough clearance to use a 1.55" shaft though.

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post #212 of 3248 Old 12-07-2010, 11:10 PM
tednelson83
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that brings up an interesting question, if my 93 46rh uses a 1.55" input shaft, why can't i just use any case with out swapping them? why do i need to swap anything?

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post #213 of 3248 Old 12-07-2010, 11:41 PM Thread Starter
JrMechanic
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Quote:
Originally Posted by Tangfan View Post
Great thread, was very helpful. Some added information that I was unable to find. Swapped a 242 TC from a 96 ZJ with a 0.840" input shaft for oiginal 249 TC with a 0.750" input shaft in my 93 ZJ with a I6 engine. transmission had significant enough clearance so that added shaft length was no issue. Was not enough clearance to use a 1.55" shaft though.
I highly recommend against this. It may "seem" like you have enough clearance, however for all you know the transmission output shaft could be bottoming out on the transfer case input. This is BAD!! You need ample end play in the output shaft, or else you will eventually tear things up.

Ted, if you used say a .840" exposed shaft with the 46RH, the splines wouldn't fully engage, and the input shaft would not come into contact with the transmission output seal.

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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post #214 of 3248 Old 12-08-2010, 01:27 PM
Tangfan
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I thought about the end play clearance as well. The available clearance in the tranny was ~ 1.5". considering that amount of avaikable clearance, figured there should not be an issue. This amount of clearance might be due to a transmission swap in my 93 since I did buy it used and it has over 200,000 miles.
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post #215 of 3248 Old 12-08-2010, 04:33 PM
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My 93 ZJ 4.0 AW4 has 237K miles on it. Tranny has never been rebuilt. Your 200K doesnt mean it was rebuilt. May very well still be OEM.
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post #216 of 3248 Old 12-09-2010, 09:10 AM
squazz
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so i just rebuilt my 231 that im gonna put in the ZJ lucky to get benzel and **** linkage off donar.So I did bearings seals and chain and SYE(in the hole for $500) getting ready to seal everything back up just aint totally sure where the magnet goes
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post #217 of 3248 Old 12-09-2010, 01:29 PM
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so i just rebuilt my 231 that im gonna put in the ZJ lucky to get benzel and **** linkage off donar.So I did bearings seals and chain and SYE(in the hole for $500) getting ready to seal everything back up just aint totally sure where the magnet goes


Look on the other TC half. There is a slot where the magnet goes.
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post #218 of 3248 Old 12-09-2010, 02:45 PM
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The AW4 in my old Cherokee had almost 400k miles when the Jeep was put out of commission. I never had a single problem with it. I would be willing to bet that yours is still running OEM parts.

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post #219 of 3248 Old 12-09-2010, 08:33 PM
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Thinking about getting me a 242 for Xmas, it should be a fun and educational project. Great info

I have a question though. I found an 88 XJ 242 on craigslist and as I understand, I can just swap in the driveshaft from the XJ, or will it be an uncompatable length since it's a different model? Since my 96 has the external slip yoke and the 88 most likely has internal.
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post #220 of 3248 Old 12-09-2010, 09:00 PM
squazz
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Originally Posted by Virmagicus View Post
Look on the other TC half. There is a slot where the magnet goes.
so it dont go on the rod with the spring cuz thats what i was trying .thanks i'll check it out 2morrow
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post #221 of 3248 Old 01-01-2011, 12:09 AM
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Thanks for a great write up. I just have one question. To swap a 231/242 into my 98 ZJ 5.2 249 I just need to find a 231/242 Tcase from the 96-98 XJ, TJ,ZJ and should work without any fuss. Or ??? The first post doesn't say anything about years of XJ or TJ T-case to use. Thanks

Tim

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post #222 of 3248 Old 01-01-2011, 06:22 PM
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You can use a 242 from a 96-98 ZJ or 97-01 XJ and its a direct swap. When i did mine all i had to do was swap the speedo gears and sending unit from one to the other. Plugs were different and different tooth gear for a different gear ratio.
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post #223 of 3248 Old 01-03-2011, 06:49 AM
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Swap finally done!

Finally got my swap done this weekend, thanks in large part to this thread.

I got really lucky in finding a transfer case. My buddy blew his 249 in his '98 Limited and was asking my advice on finding one. We looked at the local classifieds and couldn't find a decent 249 for his truck. What we did find, however, was a recently rebuilt (incl chain) 242 from a 2000 XJ with a Tom Woods SYE kit ALREADY INSTALLED. Guy only wanted $300 for it, too. Said that the case was fine, he just swapped to a 231 and was trying to get rid of it.

Talked him down to $275 and then split the difference with my buddy, as I told him I would give him my perfectly functional 249 that was in my 5.9 once I did the swap. So, all in all, I paid $140 for a rebuilt 242 with an SYE kit already installed. I feel like I got a good deal.

Just got to give Tom Woods a call this morning to get a new rear driveshaft on the way. I currently have a front-wheel-drive Jeep. So, I haven't been able to do the obligatory 2WD burnout yet, lol.

BTW, and I'm sure this information has been posted already, but I changed the transmission output seal while I was in there. It appeared as though my existing one was fine because it was bone dry in between the tranny and t-case, but I figured it was cheap insurance. The part number for this seal is 710058 (Timken). This is listed the same for 42RE and 46RE, so I6 or V8 shouldn't matter.

I also did the double-lip seal upgrade on the input seal of my t-case. Again, figured it was cheap insurance. Part number for this seal is 710928 (Timken). This is actually the input seal for a Chevy NP241 t-case. If that number doesn't work at your parts house, just have them look up the seal for a 1990 Chevy 1/2-ton pickup (4x4, obviously). This should yield the right seal. Take it out of the package for confirmation. It will be very obvious to you if the seal you get is a "double-lip" style.

Again, thanks for all the help on this thread!
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post #224 of 3248 Old 01-03-2011, 07:18 PM
PlatinumNiner
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Dont drive a V8 ZJ in front wheel drive. Your D30 wont last very long doing that. Are you lifted or stock height?
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post #225 of 3248 Old 01-04-2011, 06:32 AM
jlipka98zj
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Quote:
Originally Posted by PlatinumNiner View Post
Dont drive a V8 ZJ in front wheel drive. Your D30 wont last very long doing that. Are you lifted or stock height?
Stock height right now. Don't worry, I'm not driving it around like that. Just drove it home from my buddy's gararge to my house like that. Never fear, it gives me an excuse to drive my other Jeep.

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