Transfer Case Swap Info NP249->NP231 & NP242 - Page 37 - JeepForum.com
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Unread 06-24-2011, 01:02 PM   #541
nadman009
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Well I drove with the new 242 in for a test drive, and the next time I started the car it flased the "Check 4WD switch" at me. So then I unplugged the red and plugged in the black. I unplugged the battery for 10 minutes and then shifted through everything with no luck. Its still flashing at me. And when you say bad bad things, what do you mean!?

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Unread 06-24-2011, 01:28 PM   #542
Candymancan
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Quote:
Originally Posted by speedbucket View Post
its normal to have spider cracks all over the inside of the case right?


Yea both my Jeeps have that, cracks and even what looks like chips on some parts. The transmission housing has those little spider web cracks on it too... As said abiove i bet its from the forging process.
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Unread 06-28-2011, 10:26 PM   #543
Ryanwill2008
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Just completed the swap from a 249 to a 242 this weekend.. followed instructions described above and had absolutely no trouble I even had to swap input shafts!
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Unread 06-29-2011, 06:30 AM   #544
speedbucket
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Quote:
Originally Posted by Ryanwill2008 View Post
Just completed the swap from a 249 to a 242 this weekend.. followed instructions described above and had absolutely no trouble I even had to swap input shafts!
will you ship me your old front case half?
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Unread 06-29-2011, 08:04 AM   #545
JrMechanic
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Sorry for any questions or PM's I've missed, it's difficult to keep up on them. I'm happy to see so many successful swaps with the help of my write up and several other members in this thread

There does appear to be some confusion as to reading the date on the tag. The last number (typically a 1, 2, or 3) indicates the assembly line it came off of, if I remember correctly. At one point I was under the impression that was the month but I was incorrect.

The correct way to read the date is just how it looks. Month, day, year. So if your case says 8 15 92 1, That would be August 15th, 1992. Most manufacturers aren't this specific on the manufacturing date which would lead you to believe "1" would be January, 1992.

Sorry for the confusion
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Unread 07-02-2011, 08:49 PM   #546
jnjtrevino
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Well did the input shaft swap today. Was very easy I was concerned that I would have the two different gear cuts but it all slid together easily.
image-2553530586.jpg   image-1866508447.jpg  
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Unread 07-03-2011, 09:16 PM   #547
Dyn0mitemat
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I have a 98 ltd 5.2 with a 249. I'm assuming it has a .840" input shaft length

I bought a 242 today for $100. Guy claims its from a 94 xj, but the tag on it shows it was built in 1991
So I can be confident the two have different gear cuts



I measured the input shaft length on the 242, and I'm getting ~.60" or so measuring it like this:


So my first question, am I measuring this right? If not, where am I supposed to measure to? All I can find is that there's a .75", .84" and 1.5" input shaft lengths, so I dunno what I have here.

Second question, assuming that I do have the .840" input shaft in my truck now, can I still use this one, or do I NEED the full .840" input shaft (can I use the shorter one, in other words?)

And third question, if I do need to switch the input shafts, being that I have two cases with different gear cuts, I should be able to use the front half and the shaft from my 249 and afix it into the 242 to make it work, correct?

Thanks in advance!

edit:
After a bit more reading it looks like I WILL have to change shafts, and in doing so it's going to be a pain because I have two different gear cuts. Now am I right in reading that I can change the input and planetary from the 249 into the 242 and be fine? Or will I have to swap the front case half as well? If so, is there any write up's on whats involved with that?
Thanks!
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Unread 07-04-2011, 10:35 PM   #548
csouers
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Quote:
Originally Posted by Dyn0mitemat View Post
I bought a 242 today for $100. Guy claims its from a 94 xj, but the tag on it shows it was built in 1991
So I can be confident the two have different gear cuts

I measured the input shaft length on the 242, and I'm getting ~.60" or so measuring it like this:

So my first question, am I measuring this right? If not, where am I supposed to measure to? All I can find is that there's a .75", .84" and 1.5" input shaft lengths, so I dunno what I have here.

Second question, assuming that I do have the .840" input shaft in my truck now, can I still use this one, or do I NEED the full .840" input shaft (can I use the shorter one, in other words?)

And third question, if I do need to switch the input shafts, being that I have two cases with different gear cuts, I should be able to use the front half and the shaft from my 249 and afix it into the 242 to make it work, correct?

Thanks in advance!

edit:
After a bit more reading it looks like I WILL have to change shafts, and in doing so it's going to be a pain because I have two different gear cuts. Now am I right in reading that I can change the input and planetary from the 249 into the 242 and be fine? Or will I have to swap the front case half as well? If so, is there any write up's on whats involved with that?
Thanks!
Your ZJ does indeed have the .840" input shaft.

I'm not sure how to measure it. I believe it is measured with the seal retainer off, but don't quote me on that. Either way, you should have the .750" input on the 242. 91-95ish with the AW4 used the .750" input.

You read correctly. You'll definitely have to swap the gears. In fact, you'll have to use the front case and the input/planetary from the 249 and several other things from it to do this swap.

You will have to drill a hole for the shift rail roll pin as well as drill and tap a hole in the front case to get to it. The 249 does not have either hole.

The front case attaches to the Jeep. The rear case has the rear output coming out of it.
I'll give you an overview of what you will need to use.

Front Case - 249
Seal Retainer - 249/242
Input Gear and Planetary - 249 - Is held together with snap rings. Can't miss it
Shift Rail - 242
Mode and Range Forks - 242
Front Output Gear and Yoke - 249/242
Rear Case and Extension Housing - 242
Speedometer Sensor and Gear - 249 - Make sure to take note of the markings on the housing to get things in the proper place. Failure to do so can result in a broken speedometer gear.
Mode Sensor - 249, however you will get incorrect readings. If the VIC connectors are swapped inside the Jeep, the sensor will read Full-Time when the case is locked 50/50. Don't drive on pavement with that lit up. Easy.
Shift sector plate - 242 - The linkage on the outside of the case attaches to this.

You'll want to put new range/mode forks (EDIT: pads not the forks!! the little plastic pieces that are on the forks. You can't miss them.) on the 242 as well as do all bearings and seals. Don't quote me on the seal retainer though. That could go either way. If something doesn't work, you'll immediately be able to try the other one. If it works, great.

Good luck with the swap.
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Unread 07-05-2011, 05:49 AM   #549
Dyn0mitemat
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Thanks, I greatly appreciate the time to write that up. If anyone else has information or write ups on swapping the front case half like I need to do please post them.
I got the 242 torn apart and it doesn't look to bad, I just don't want to miss anything as far as swapping cases/halfs
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Unread 07-05-2011, 05:27 PM   #550
Dyn0mitemat
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Alright so I got the rest of the 242 apart, I'm planning on using the front yoke from the 249 case so I don't have to screw with the nut on it and torquing it correctly.
Besides that, the input gear/planetary and mode (which I don't really care about) and speedo sensors, I should be able to use just about everything else from the 242 then right?


You say I need to drill a plug for the shift rail roll pin, as well as a hole to access it ? Am I not re-using all the shifting rail parts from the 242? I was assuming I was, hence I wouldn't need to redrill that.


Will I be able to just drill and reuse the rubber plug from the 242 case on the 249 (to get the roll pin out)? Or should I drill, pipe tap, and plug?

And which part is the seal retainer? The part the extends out the back housing the internal slip yoke for the rear drive shaft?
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Unread 07-05-2011, 07:05 PM   #551
csouers
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Not sure if you can get the chain out without taking the front output out. If so, more power to you.

The rail from the 242 is being used again, yes. However, the 249 does not have the hole to access the hole nor a hole in the aluminum to insert the roll pin, while the 242 has both.
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Unread 07-06-2011, 11:35 PM   #552
Blwn89gt
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I've really been kicking around the idea of doing this. I wanted to do it when i put my new tranny in, but was in the middle of building my mustang so i decided agsint it at the time. Seems like the tech article is very informative and i might take this on.
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Unread 07-07-2011, 06:22 AM   #553
speedbucket
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Quote:
Originally Posted by csouers View Post
Not sure if you can get the chain out without taking the front output out. If so, more power to you.

The rail from the 242 is being used again, yes. However, the 249 does not have the hole to access the hole nor a hole in the aluminum to insert the roll pin, while the 242 has both.
do you think the 249 case is thick enough to tap threads and use a bolt as the roll pin?
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Unread 07-07-2011, 07:14 AM   #554
csouers
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Quote:
Originally Posted by speedbucket

do you think the 249 case is thick enough to tap threads and use a bolt as the roll pin?
The bolt would only be to stop fluid from pouring out.

Honestly, I'm second guessing myself on this rollpin business. My dad did the drilling, so I can't recall exactly what had to be done. All I know is that the rubber stopper on the 242 can be reused on the 249. Just don't drill the hole too big. Start small and move your way up.
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Unread 07-07-2011, 10:38 AM   #555
Dyn0mitemat
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I got the 249 out and apart last night, very easy to find where to drill the hole. I did not have to drill the a hole in the aluminum for the roll pin like you said, only the one to access it. Neither of my cases had that so I didn't put one back.it was going on midnight last night as I was dropping the mainshafts back into the case, gotta put the chain and rest on, and put it in tonight
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