Transfer Case Swap Info NP249->NP231 & NP242 - Page 34 - JeepForum.com

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post #496 of 3196 Old 05-18-2011, 08:35 PM Thread Starter
JrMechanic
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Quote:
Originally Posted by ny_driver View Post
Looks good!

OK.......now if the newer T-case has the same .750" 23 spline input shaft, does the gearcut change make any difference to me? Can't do a front case swap because of the gearcut change. My 249 was built in 1992.

Will the input shaft hook up correctly to the tranny or is it cut differently?
You should be able to bolt the transfer case right up to your transmission.


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 #497 of 3196 Old 05-18-2011, 08:52 PM
ny_driver
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Great!

I was reading today and I was getting worried about the gearcut change. So although the input, sun, and annulus gears were changed, the input shaft and splines will still be the same?
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post #498 of 3196 Old 05-19-2011, 06:59 PM
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I just bought this one here...........
http://cgi.ebay.com/ebaymotors/ws/eB...K%3AMEWNX%3AIT

Either it will bolt in or I'll have to do a case swap if input is the wrong length. They better be right about what it is. I'll call them tomorrow, I couldn't let that slip by for $185.
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post #499 of 3196 Old 05-31-2011, 01:12 PM
ExpeditionXJ
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Trying to read through some of this thread has my head spinning.. hoping someone can help me.

I'm parting an XJ, with an 88 NP242 21 spline, unsure of input length. I see it's pre 94.5 so i have the early gearcut. This case is SYE'd, newer chain and brand new seals and bearings.

I'm building a 98 ZJ which has factory 242. I read that i have the .840" input, i know it's 23 spline and with the later gearcut.

I'm going to lose a ton of money i have in the XJ 242 if i have to sell it, and repurchase the rebuild kit and SYE again for the ZJ's 242 at full retail.

Can i simply swap the ZJ's input and surrounding gear into the XJ case and bolt it into ZJ? Or can i swap the XJ's mainshaft and back case half into the ZJ's front case half like i would for a 249>242 swap?

I'm not too up to speed on the early/late 242 internal parts and compatabilty of mixing them.

EDIT:

Just had another thought. I could source a 23 spline, .840" input, from a pre 94.5 with early gear cut, swap into the XJ case and bolt it up... right?
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post #500 of 3196 Old 05-31-2011, 02:22 PM
blackls1ttop
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i just went under there on my 1995 jeep GC with the 249 and it has a date of 8 13 94 1 8-13-94 so i have the new gear cut? if i do will a 1996 and up transfer case work?
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post #501 of 3196 Old 06-01-2011, 05:08 AM
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The gearcut change only affected the internal gears, so if you have a 23 spline and the correct length input shaft it will bolt right to the tranny. If you are using a newer t-case with the external slip yoke then you'll also need to swap rear drive shafts.

I suggest measuring the length of the exposed part of the input shaft. There is no other way to be certain.
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post #502 of 3196 Old 06-01-2011, 09:08 AM
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Ok
ive been studyin up for a while and just want to reassure myself

i have a 93 v8 with 46rh
a 249 with the 1.55" input and internal slip yoke

I bought (80$) a 93 born 242 with the .8" input and a internal slip yoke

i know i have to swap inputs but gearcut will be the same
Is there a reccomended rebuild kit for the 242? (bearings, seals, and chain)
is there anywhere i can just buy the 1.55" input? bc my 249 is still functional and i would like to sell it after the swap

http://www.jeepforum.com/forum/f22/speedbuckets-zj-build-1361322/
V8 zj at 6" . Double tri rear and true 3 link front. Stretched to 108"
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post #503 of 3196 Old 06-05-2011, 10:43 PM
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Quote:
93-95 I6 ZJ's: Used both the .750" and .840" 23 spline input with the 42RE and AX15.
Maybe a dumb question but is there any way to tell if it will be a .750 or .850 without actually pullin it???

I'm looking at pullin a 231 out of a 94 ZJ and replacing the tc in my 97.

Thanks!

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post #504 of 3196 Old 06-06-2011, 06:32 AM
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Figure out the year of your Jeep, manufacture date of the T-case(small circular metal tag on back side), and what transmission and T-case it has. We should be able to figure it out, although there's no way to be certain without measuring.

For example: I know mine is the .750" input shaft without measuring because it is a 93ZJ with I6 and AW4 tranny/249 T-case. I'll look for the info I used to figure it out. All I did was look at all the T-case swap info google could find for me.

EDIT: Here ya go........guess that doesn't really help huh? .
93-95 V8 ZJ's: 46RH transmission, 1.55" 23 spline input shaft
93-95 I6 ZJ's: Used both the .750" and .840" 23 spline input with the 42RE and AX15.
93 I6 ZJ's with the AW4: .750" 23 spline input
All 96-98 ZJ's: .840" 23 spline input

I found some good info for you.
http://www.novak-adapt.com/knowledge...nput_gears.htm

(the following taken from the previous link)

Input Gears and Compatibility
Hold on to your seat...

The important variations to look for in the 231 transfer case are in the input gear. The 231 comes in 21 spline and 23 spline versions with long, medium (rare) and short variations.

The long shafts protrude 2.1" from the front mounting face of the transfer case. The short version protrudes 1.2". The rare medium shaft protrudes 1.7". You should be careful when swapping any of these gears due to different bearing widths and gear teeth. The following chart shows how to determine which input gear you might have by transmission. It is always recommended to verify first hand if possible.

21 Spline 23 Spline
Short Input AW4 (through 1990)
AX4
AX5
Peugeot BA 10/5 (earlier) Earlier (pre-'95) AX15

Long Input Later (post-'94) AX15
TF904
TF999
Peugeot BA 10/5(later)
NV3550
NSG370
Medium Input 46RE Jeep ZJ's '93 to '95 only
AW4 (post-'90)

Because of differences in the cut of the gear, as a general rule, one should not interchange 1987-1993 gears with 1994-present gears. These years are not always hard and fast delineations. If one is not absolutely certain, disassembly and inspection is required.

Note that some transmissions change spline count. The Peugeot BA10/5 had both 21 or 23 splines. The AW4 had 21 splines through 1990. In 1991 (the same year the 4.0 HO was introduced) the AW4 splines increased to 23.

ReEDIT:Looks like all 97ZJs have the .840" shaft. I'd look for one that is already pulled and measure the exposed part of the shaft. If you have a 97 and you go with an older one you may have to also swap rear driveshafts. I'm going from a 93 249 case to a 97 242 case and I need to change rear driveshafts. 93 has internal slip yoke, and 97 has external. I hope some of this was helpful.

Last edited by ny_driver; 06-06-2011 at 08:03 AM.
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post #505 of 3196 Old 06-06-2011, 10:49 AM
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how much for a 242 case for a 96 zj 5.2v8 w 44re tranny to 28546
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post #506 of 3196 Old 06-07-2011, 06:48 AM
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Quote:
Originally Posted by rob_kennedy View Post
how much for a 242 case for a 96 zj 5.2v8 w 44re tranny to 28546
This isn't a For Sale thread. They cost ~$250 shipped.

EDIT: ohh my bad I guess it is a F/S thread
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post #507 of 3196 Old 06-13-2011, 01:57 PM
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'95 Grand 5.2 249-231 swap

This thread is making my head hurt. Just have 1 question that will probably turn into many. I recently got a 231 out of a '06ish tj unlimited (for free, no problems with case. case was replaced do to a snapping sound and turns out it was the rear diff gears) and want to swap it into my 1995 grand cherokee laredo V-8 5.2 My grand has the 249 and build date on case says 001016. 231 case has no build date but serial number says: 03 07 06 c3 (looks like a date to me) the 231 has a 23 spline input. I'm not sure on what to measure for the length of the input and unsure of the '95 splines/lenght. i know I probly have to remove the case from my 95 to count and measure but the 95 is my daily driver so down time is not really an option. does anyone know what I might need to change to perfom this swap? Will supply and other info needed as best can
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post #508 of 3196 Old 06-13-2011, 08:36 PM
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I doubt that transfercase will work its so new the bolt patterns are probably totally diff

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post #509 of 3196 Old 06-14-2011, 07:45 AM
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Quote:
Originally Posted by Candymancan
I doubt that transfercase will work its so new the bolt patterns are probably totally diff
Doubtful. You can always redrill the stud holes. The problem with a newer case is the speed sensor or lack thereof.

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post #510 of 3196 Old 06-14-2011, 08:05 AM
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Originally Posted by csouers View Post
Doubtful. You can always redrill the stud holes. The problem with a newer case is the speed sensor or lack thereof.
yes, if my memory serves me correctly then anything after 99 has no speedo sensor hole, but the bolts are the same and im not sure about the input

http://www.jeepforum.com/forum/f22/speedbuckets-zj-build-1361322/
V8 zj at 6" . Double tri rear and true 3 link front. Stretched to 108"
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