Transfer Case Swap Info NP249->NP231 & NP242 - Page 38 - JeepForum.com
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Unread 07-07-2011, 12:29 PM   #556
csouers
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Quote:
Originally Posted by Dyn0mitemat
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
Hmm okay awesome! Good luck with the rest!

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Unread 07-07-2011, 04:07 PM   #557
Came2ride
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Ok so I have 2 t cases in my shed torn apart but I cannot find the input shaft I need anywhere. I'm going from a 249 to a 231 and I need a 1.55 with the newer gear cut. Does anyone know why application I could find this in. I guess it's too hard for auto part stores and junkyards to know the specs all they wanna know is year make and model
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Unread 07-08-2011, 05:16 PM   #558
TewSmooth18
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does anyone happen to know how long the input shaft is from the seal to the end of the input shaft for one that is .840 in length? I've measured the one on the 242 i got and it's about 7/8ths from the seal to the end of the input shaft. does this happen to sound right for the .840 input shaft? just curious to know in advance prior to pulling my TC. Dont want to start ripping the 242 case open to get it ready to swap input shafts if I don't have to.
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Unread 07-08-2011, 05:18 PM   #559
TewSmooth18
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Quote:
Originally Posted by Came2ride View Post
Ok so I have 2 t cases in my shed torn apart but I cannot find the input shaft I need anywhere. I'm going from a 249 to a 231 and I need a 1.55 with the newer gear cut. Does anyone know why application I could find this in. I guess it's too hard for auto part stores and junkyards to know the specs all they wanna know is year make and model
quoting from the first page of this thread

"It's best to go by the build date on the transfer case, not the year of the Jeep when determining the gear pitch. Rule of thumb is cases with a build date of pre 94.5 will have the old style gear cut, and cases with a build date of post 94.5 will have the new style gear cut."
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Unread 07-08-2011, 06:38 PM   #560
csouers
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Quote:
Originally Posted by TewSmooth18

I have a 1.55 input shaft from a 249 that I don't need...it was assy in 93 so im not sure about the gear cut. if you think it might work shoot me a PM
I've never seen a 1.55" late-cut input. All ZJs 96-98 used .840". You might look into WJ inputs. Not sure what they have.
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Unread 07-08-2011, 07:34 PM   #561
TewSmooth18
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Quote:
Originally Posted by csouers View Post
I've never seen a 1.55" late-cut input. All ZJs 96-98 used .840". You might look into WJ inputs. Not sure what they have.
Yeah, I editted my post as he said he needed the new gear cut and mine is from a 93 TC so it would have the old gear cut..

as far as how long the input shaft is, i've got it figured out. I never thought about busting out the digital calipers so I did that. so this is to help others out. if you use digital calipers and measure from the seal to the end of the input shaft with the digital calipers it will tell you how long it is. I just set my calipers to 0.840 and put it from the seal to the end of the shaft and it was correct, so I tried it on my input shaft that is the long one and set the caliper to 1.550 and it was the exact length as well.

So yeah, as far as measuring it's from the seal to the end of the input shaft (what's exposed)
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Unread 07-08-2011, 08:42 PM   #562
Blwn89gt
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someone correct me if im wrong but i belive the transfer case out of a 98 durango with 5.2 in it will work on my 98zj with 5.2 I crawled under my fathers durango and it says model 42 on the tag, it has same motor, same tranny as my zj and essentialy is the same truck.
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Unread 07-09-2011, 01:28 PM   #563
TewSmooth18
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I have 1 last question before doing this swap. Do I need to remove the shift linkage bar that's on the TC from the 249 and put it on the 242 or do I leave the one that's on the 242 on there? It is shorter then the 249 so not sure if I am supposed to swap the one from the 249 onto the 242 or not???
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Unread 07-09-2011, 02:46 PM   #564
Dyn0mitemat
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I had to use the one from the 242

Id keep both handy just incase though
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Unread 07-09-2011, 08:02 PM   #565
Came2ride
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I went by build date and I have both t cases apart I know I need a 1.55 with the new gear cut, I'm just curious if anyone knows what application this would be found in
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Unread 07-09-2011, 08:41 PM   #566
TewSmooth18
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Quote:
Originally Posted by Came2ride View Post
I went by build date and I have both t cases apart I know I need a 1.55 with the new gear cut, I'm just curious if anyone knows what application this would be found in
no idea, but if you happen to find out you need the 1.55 with the old gear cut, i've got one I will let go
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Unread 07-10-2011, 08:01 AM   #567
TewSmooth18
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ok, so I thought I only had 1 other question. but I guess I have another one. when doing the 242 swap, do you have to swap "Both" sensors from the 249 into the 242 or just the speedometer sensor?? I know I have to swap the speedometer sensor because the plugs are different, but do I need to swap the shift indicator sensor as well?
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Unread 07-10-2011, 08:38 AM   #568
comptiger5000
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I only swapped the speedo sensor when I did mine.
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Unread 07-10-2011, 09:43 AM   #569
JrMechanic
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Quote:
Originally Posted by Blwn89gt View Post
someone correct me if im wrong but i belive the transfer case out of a 98 durango with 5.2 in it will work on my 98zj with 5.2 I crawled under my fathers durango and it says model 42 on the tag, it has same motor, same tranny as my zj and essentialy is the same truck.
The 242d will have different outputs than the 242j. It's not worth trying to make a 242d work when 242j's are in such abundance.

Tewsmooth, use the shift tab from the 242, speedometer sensor from the 249, and leave the other sensor alone. It is different from the 249 sensor, however there is still a good chance you won't be able to hook up the 242 sensor.

came2ride, the only cases with a late 1.55" input would be a 249 built in very late '94-early '95, after that they would have stopped manufacturing the 249 with the long input shaft.

Your best bet is to get a different 231.
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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 07-10-2011, 11:56 AM   #570
TewSmooth18
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Quote:
Originally Posted by JrMechanic View Post
Tewsmooth, use the shift tab from the 242, speedometer sensor from the 249, and leave the other sensor alone. It is different from the 249 sensor, however there is still a good chance you won't be able to hook up the 242 sensor.
why wouldnt i be able to hookup the 242 sensor (shift indicator)? from what it looks like, the plugs are exactly the same on the 242 and the 249 that i have
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