Transfer Case Swap Info NP249->NP231 & NP242 - Page 39 - JeepForum.com
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Unread 07-10-2011, 01:56 PM   #571
csouers
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Quote:
Originally Posted by TewSmooth18

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
The sensors are the same. If the location is the same on both transfer cases, plug it in and swap the VIC plug inside the jeep. Done.

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Unread 07-11-2011, 11:24 PM   #572
TewSmooth18
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So I did the 242 swap today, everything went great, found the plugs for the VIC, got the linkage adjusted and it shifts into all gears. BUT. I've got a problem. the 242 i got had the external slip yoke, so I had to get a shorter drive shaft, well, i grabbed a shorter drive shaft off another 98 jeep (242 was pulled from a 98) that also had the external slip yoke, went to put the rear drive shaft on, and the damn thing only slides onto the output shaft about 1 1/2 inches. maybe a little less then that. wtf?? how far is the drive shaft supposed to be on the output shaft for the rear drive shaft? my original drive shaft is not even 1/2 inch shy of being able to slide on, it's shy of 1/2 being to long. (from the 249 with internal slip yoke). appears i'm gonna have to have my original drive shaft shortened about an inch beings the one i grabbed that's shorter appears to be TO short

also, if anybody is interested, i have for sale i 2 input shafts, 1 is a 1.55 and the other is a .840. also have 2 front case halfs from 249's.
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Unread 07-21-2011, 04:31 PM   #573
Came2ride
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Update: if you are having trouble finding the input gear you need. Go to www.Novak-adapt.com and call them that can look up what you need by the specs instead of year make and model like every other company does. Very helpful and the got my part out quick

Last edited by Came2ride; 07-21-2011 at 04:32 PM.. Reason: Mistype
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Unread 07-25-2011, 12:34 PM   #574
Mediokrates
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I have a 93 Grand Cherokee Limited 5.2L V8.
I think the visous coupling has worn out.
I believe I have the NP 249 AWD transfer case, (so I'm told... High, Neutral, Low)

Due to money and for simplicity's sake, I was considering just swapping out the VC or swapping in a used 249 transfer case, for the time being.

Since the jeep is a 5.2L, would this mean that the transfer case is the 5.2/46RH/249, or are there other variants. If so, are they interchangeable? I am curious b/c I've found a used 249 transfer case out of a 95 GC, and am curious as to what questions I need to ask the seller to ensure compatibilty.

If doing a straight swap 249 for 249, other than draining, swapping out, and refilling with ATF, what else would need to be done?

Thanks

Last edited by Mediokrates; 07-25-2011 at 12:54 PM..
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Unread 07-25-2011, 08:13 PM   #575
csouers
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Quote:
Originally Posted by Mediokrates View Post
I have a 93 Grand Cherokee Limited 5.2L V8.
I think the visous coupling has worn out.
I believe I have the NP 249 AWD transfer case, (so I'm told... High, Neutral, Low)

Due to money and for simplicity's sake, I was considering just swapping out the VC or swapping in a used 249 transfer case, for the time being.

Since the jeep is a 5.2L, would this mean that the transfer case is the 5.2/46RH/249, or are there other variants. If so, are they interchangeable? I am curious b/c I've found a used 249 transfer case out of a 95 GC, and am curious as to what questions I need to ask the seller to ensure compatibilty.

If doing a straight swap 249 for 249, other than draining, swapping out, and refilling with ATF, what else would need to be done?

Thanks
Putting in a new VC is expensive (often more than a 242) and a good used 249 is like finding a needle in the haystack. I bought my 242 for $250 and will be putting in a rebuild kit for security, although I could probably get away without it.

Buy a 242 and post up the build date on the tag. The 242 and 249 share similar front case sections (part that bolts to the transmission) and are inter-changeable. You will likely lose the mode sensor due to the design change of the front case and shifter plate, but mechanically, it will work. I ran into this issue on my 96 5.2, but it's been the best thing I've done to that Jeep.
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Unread 07-26-2011, 06:19 PM   #576
Mediokrates
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Thanks csouers

Money's a little tight right now, so I'm looking at something cheap, even if it only buys me a year's use. I don't mind doing the work again next year.

EDIT:

Sorry if I'm repeating myself, or asking questions that have already been answered. I've been educating myself a bit, reading more of this thread and other related posts.

To summarize... I have a 93 Grand Cherokee Ltd, 5.2L V8, auto trans, with a 249J TC. The build date on the TC is 3 31 93. I am assuming it is has an Internal Slip Yoke, as the rear output shaft is covered by a cone as pictured below. Lengths are given.



1. Am I correct in this? Also, would I be correct in assuming that this is a 5.2/46RH/249? Would this be an NP or NV series? What's the difference?
2. Would this then have a 1.55" input shaft with 23 splines, and outputs with 27 splines?

Due to monetary concerns, I am considering a straight 249-to-249 swap (or VC swap), or a 249-to-242.

3. If performing a 249-to-249 swap, what are my concerns? How can you confirm if a VC is still good? The possible donour TC is dated 3 11 94. It appears to be ISY. It also appears to have a 1.55 input shaft (is longer than bolts around it).

4. If performing a 249-to-242 swap, my possible donour is a 242J with a build date of 1 18 94. It appears to be ISY. I don't know what model it came from, engine size, or trans. Does this matter? It appears to have a shorter input shaft. EDIT: the 242 comes from a 94 GC, 4.0L, 23 splines input, 27 splines output.

5. How can you tell if a 242 is still good?

6. I understand that if performing the 249-242 swap, I would probably have to swap out the input. If necessary is it easiest to swap planetarys? What's the difference with a front end swap?

7. With the examples I have given... would I need to worry about the front output shaft/yoke and/or drivetrains. When is that necessary?

8. I'm really confused about the "annulus gear cut change" mid 94. What exactly is that? and would that apply in these cases?

9. What am I missing?

10. Lastly, can anyone tell me if this notch out of the trans housing where it meets the TC is normal? It appears to be leaking some ATF.



Thanks again everyone.

Any help is greatly appreciated

Last edited by Mediokrates; 07-27-2011 at 05:46 PM.. Reason: Update
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Unread 08-05-2011, 12:49 PM   #577
V852
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Finally it is done - I have an NP242 inside.

The front of my old 249 was combined with the back of an 1988er 242er. And this was very easy.

Here the steps in the on-board computer:









I don´t know why here´s appearing "Part Time".

And my self-made bezel:
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Unread 08-05-2011, 08:06 PM   #578
TewSmooth18
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no idea why they have it say "part time" for 4 lo because it shows 4 lo when you have the 249. pretty dumb if you ask me, but that's just the way that it is.
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Unread 08-05-2011, 10:28 PM   #579
csouers
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Quote:
Originally Posted by Mediokrates View Post
Thanks csouers
To summ

Any help is greatly appreciated
No problem. Now, answers to your questions.

1. Yes. It is the NP series. The NV name change started somewhere around 99, but in my ZJ service manuals, the transfer cases are listed as NV, NOT NP. I guess you could say that things happened "ahead of schedule". The major change in the 242 occurred around the same time that the gear cut changed, mid 94. At that point, the 242 went to external slip yoke for the rear and possibly changed the mode sensor styling (not sure on that one).

2. Yes, the 46RH used the 1.55" input shaft. All Jeep cases 91+ are 23 spline input.

3. The only way to tell is to install it and go for a drive. After a decent length of a drive with a mix of highway and city driving, try to do tight figure 8s in a parking lot and if you get binding and hopping, the VC is no good.

4. That would be a great swap donor. Swap the input shaft and speedometer gears (read the instructions on that one) and go.

5. Chances are the 242 is fine. I have yet to see a 242 fail mechanically, however, stretched chains can and do sometimes break. Replace it for safety's sake. As far as testing without installing it, run it through all the modes. In full time you should be able to hold one output and spin the other, as if in an open differential, much like in your axles.

6. You can simply pull the entire planetary set that holds on the input and drop it in the 242. You don't have to deal with annulus cut issues, unless you have the late cut style in your 249. That's highly unlikely, considering the date of your 249, but weirder things have happened.

7. Going from ISY to ISY, driveshafts should be direct bolt in. I don't suspect any issues. However, measure both cases from mounting point on the trans to the rear-most point on the rear output to be sure.

8. The annulus gear is the ring gear on the inside of the front case (bolts to trans). This gear cut changed, along with the gear of cut of the planets and sun/input gear around 94.5 as did the output style. Using a early cut planet/input set in a late cut annulus will = death. They must be machined to match as done from the factory. You should have no problems with this.

9. Nothing! I would recommend you do an overhaul on the 242. Novak sells a nice overhaul kit that includes everything, even the chain for around $250 shipped. You will need the earlier np-242 kit. http://www.novak-adapt.com/catalog/2..._242_parts.htm

10. Sorry to say, but that is not a notch. The aluminum has broken there, thus the leak. You may be able to take it to a shop and have them fix it. I'm not fan of the jb-weld stuff, but that may be your only *cheap* option. Not the greatest, but if it works, it works. If you do go the JB-weld route, do it while the tcase is off.

Best of luck.
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Unread 08-06-2011, 08:30 AM   #580
comptiger5000
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The reason the VIC shows Part Time in 4lo is that the sensor is in the same position. It only reads 4wd type selection, not gear range selection. Thus, the VIC doesn't know the difference. The 249 is different, having only 2 modes (plus neutral), so it senses high vs low, rather than 4wd type.
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Unread 08-06-2011, 10:11 AM   #581
V852
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Thanks for the explanation comptiger5000
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Unread 08-07-2011, 05:07 PM   #582
Mediokrates
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Thanks Csouers!

One last question...

Does the engine size matter? Meaning will a transfer case from a 4.0L fit a 5.2?

It seems to me from the original post by JrMechanic, that an early 94 242 from a 4.0L with a 42RE tranny would fit my vehicle, 93 GC Ltd, 5.2, 46RH tranny.
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Unread 08-07-2011, 08:54 PM   #583
TewSmooth18
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Quote:
Originally Posted by Mediokrates View Post
Thanks Csouers!

One last question...

Does the engine size matter? Meaning will a transfer case from a 4.0L fit a 5.2?

It seems to me from the original post by JrMechanic, that an early 94 242 from a 4.0L with a 42RE tranny would fit my vehicle, 93 GC Ltd, 5.2, 46RH tranny.

You're probably gonna want to go with one from a 4.0. I have the 5.2 and my 242 came out of a 4.0
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Unread 08-08-2011, 06:01 AM   #584
speedbucket
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Quote:
Originally Posted by Mediokrates View Post
Thanks Csouers!

One last question...

Does the engine size matter? Meaning will a transfer case from a 4.0L fit a 5.2?

It seems to me from the original post by JrMechanic, that an early 94 242 from a 4.0L with a 42RE tranny would fit my vehicle, 93 GC Ltd, 5.2, 46RH tranny.
the only thing that will bolt straight up(direct swap) to a 46rh (long input) is a tcase that came from a 46rh (249 only) or has had the longer input swapped into it
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Unread 08-08-2011, 09:45 AM   #585
Devanzj
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I just (almost) completed the 231 swap but i have a couple questions. 1) the two plugs on top of the t case are different. I have read that the shift indicator sensor wont work with the 231 so I'm guessing that's what one of those is, but what's the other one?
2) Anyone know off hand what size the fill plug is for the 231? It isnt a 30mm, it looks like I need a pretty big allen key but I dont want to go out and buy 10 different ones just to get the right size.
Thanks!
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