Transfer Case Swap Info NP249->NP231 & NP242 - Page 20 - JeepForum.com
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Unread 02-20-2011, 05:57 PM   #286
mark4370
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Quote:
Originally Posted by PurpleZJ
^TSI not STI bud....
Ya LOL sorry.

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Unread 02-20-2011, 06:08 PM   #287
PlatinumNiner
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lol yea STI would be a subi. Anyway pull the front shaft out and drive it for a while. Thats pretty much how it will feel with the 242 swap.
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Unread 02-20-2011, 06:23 PM   #288
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[/IMG]
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It's a 97 STI .
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Unread 02-20-2011, 06:39 PM   #289
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Quote:
Originally Posted by PlatinumNiner
lol yea STI would be a subi. Anyway pull the front shaft out and drive it for a while. Thats pretty much how it will feel with the 242 swap.
Is that ok to do! I read sum where its bad for it.
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Unread 02-20-2011, 07:51 PM   #290
PlatinumNiner
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93-95 you cant do it 96-98 it's perfectly safe. Ran that way on my 98 5.9 for the whole summer till the threat of snow came so i put my 242 in lol
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Unread 02-22-2011, 04:51 PM   #291
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Ok i fond a 94 ZJ I6 with a 242 and a ds can i use it in my 97 ZJ I6 as a direct bolt in ?
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Unread 02-23-2011, 10:18 AM   #292
Grandplans
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What do you currently have in your '97 ZJ? Is it a 249 or a 242? If it is 242 and they are both from I6's, should be a direct swap. If it is a 249, there are minor differences, but should still be swappable. The shift bezel for a 242 is different than a 249. I've seen on this thread where people appear to have gotten the 249 linkage to work with a 242 as long as you have the shift plate on the transfer case from the 242. I'm doing a 242 swap from a 93 ZJ into my 97 ZJ with a 249. Both are from I6 engines. Sounds like we might be doing the same swap. I might get to it this weekend. If I do, I'll let you know of any issues encountered.
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Unread 02-23-2011, 10:31 AM   #293
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Quote:
Originally Posted by Grandplans
What do you currently have in your '97 ZJ? Is it a 249 or a 242? If it is 242 and they are both from I6's, should be a direct swap. If it is a 249, there are minor differences, but should still be swappable. The shift bezel for a 242 is different than a 249. I've seen on this thread where people appear to have gotten the 249 linkage to work with a 242 as long as you have the shift plate on the transfer case from the 242. I'm doing a 242 swap from a 93 ZJ into my 97 ZJ with a 249. Both are from I6 engines. Sounds like we might be doing the same swap. I might get to it this weekend. If I do, I'll let you know of any issues encountered.
I have a 97 I6 and going to a 242 from a 249 . Let me no Howe it go's . Thanks man..
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Unread 02-23-2011, 12:41 PM   #294
speedbucket
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^ dont know if the gear cut change anything for that swap but it says you check the transfer case born date and it changed in mid 94 and yours is a 97 (the later gear cut)
so if that 242 case is born before 94.5 then it will not work as a direct swap, you have to swap inputs
even though the spline count is same going from i6 to i-6 the gear cut is different. correct anybody?
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Unread 02-23-2011, 06:36 PM   #295
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Quote:
Originally Posted by speedbucket
^ dont know if the gear cut change anything for that swap but it says you check the transfer case born date and it changed in mid 94 and yours is a 97 (the later gear cut)
so if that 242 case is born before 94.5 then it will not work as a direct swap, you have to swap inputs
even though the spline count is same going from i6 to i-6 the gear cut is different. correct anybody?
I don't now the born dat is on it. But i thought changing the input shaft is for the v8's not the I6 but I don't now sum help???
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Unread 02-24-2011, 08:40 AM   #296
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There are multiple lenght input shafts. The I6's appear to use one of the 2 shorter ones. .840 or .750. From what I can tell, the V8's used a 1.55. Since you have a 242 from a '94, it should be one of the shorter ones AND have 23 splines since it is from a ZJ. So, no swapping of input shafts required. HOWEVER, I pulled my 249 from my '97 ZJ last night (has an I6 with 42re tranny, should be like yours) and the input shaft of the 249 is .840. The '93 242 that I have has a slightly shorter input shaft length and appears to be .750. I'm a bit concerned about the input shaft not being long enough for the seal into the rear of the tranny. I took some quick measurements and it's going to be close to the chamfer on the shaft, so it might leak. I will take some more detailed measurements tonight and post here. The splines from the 242 and the tail shaft of the trany are plenty long so there shouldn't be an issue there. I'm worried about the seal now. If your 242 that you have out of the '94 ZJ is .840 in length and has 23 splines, should be a direct bolt in. If it is .750, I'll let you know what I find out...
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Unread 02-25-2011, 09:21 AM   #297
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to try and clarify in shorter words, haha
aside from spline count and input shaft length
a gear cut change in mid 94 happened (not positve that it was i-6 and v8, wish someone would clarify)
so your 97 is the later gear cut
the 94 zj TC you refer to more than likely has the older gearcut
to find the borndate on the tc, on the back side of it, left of the rear output, you will have a round ID tag
On post #276 of this thread you will see a pic of that tag
the one in the pic has "12 6 94" as the serial number
that means the case was manufactured on dec. 6 1994
i believe if you have the 2 different gear cuts everything will seem to go together fine but it will whine something terrible if you use the 2 different cuts together
so if you find a donor TC manufactured after 95, it should be a direct swap
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Unread 02-26-2011, 03:10 PM   #298
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Originally Posted by Grandplans View Post
There are multiple lenght input shafts. The I6's appear to use one of the 2 shorter ones. .840 or .750. From what I can tell, the V8's used a 1.55. Since you have a 242 from a '94, it should be one of the shorter ones AND have 23 splines since it is from a ZJ. So, no swapping of input shafts required. HOWEVER, I pulled my 249 from my '97 ZJ last night (has an I6 with 42re tranny, should be like yours) and the input shaft of the 249 is .840. The '93 242 that I have has a slightly shorter input shaft length and appears to be .750. I'm a bit concerned about the input shaft not being long enough for the seal into the rear of the tranny. I took some quick measurements and it's going to be close to the chamfer on the shaft, so it might leak. I will take some more detailed measurements tonight and post here. The splines from the 242 and the tail shaft of the trany are plenty long so there shouldn't be an issue there. I'm worried about the seal now. If your 242 that you have out of the '94 ZJ is .840 in length and has 23 splines, should be a direct bolt in. If it is .750, I'll let you know what I find out...
It works great! Been driving around all day. No leaks. It looks like the rear trany seal to the edge of 242 shaft is about 3/16". A little close, but keeps the fluid in. So, if you're using a .750 length shaft where you had a .840 before, it shouldn't be a problem. This of course is all behind a 42re trany.
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Unread 02-26-2011, 03:19 PM   #299
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Quote:
Originally Posted by Grandplans

It works great! Been driving around all day. No leaks. It looks like the rear trany seal to the edge of 242 shaft is about 3/16". A little close, but keeps the fluid in. So, if you're using a .750 length shaft where you had a .840 before, it shouldn't be a problem. This of course is all behind a 42re trany.
What did you do with your DS ?
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Unread 02-26-2011, 03:54 PM   #300
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DS means drive shaft? Fit right in. The 242 transfer case overall is about 1/4" shorter than my 249. You just see a little more shiney part of the driveshaft sticking out of the rear seal is all.
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