Everybody sez to get a good pair of snap ring pliers to do this swap. Are all these snap rings the external type? Are the pliers straight or 90 degree?
Can anyone just give me a name and model number for a good pair?
Just get a good universal set (craftsman makes a pair that I've used EVERYWHERE) and you'll be golden. Get some lock ring pliers too. Using snap ring pliers on lock rings is a quick way to break tools.
(broken)98 ZJ 5.9
UT Jeepcrew #13
just did my 242 swap in my 98 5.9... donor was a 96.5 zj with an external slip yoke, swap went well minus me F'in up the output shaft seal. the only problems i ran into was the rear DS which i ended up just cutting the shaft on the TC and cutting the yoke on the DS, and the current problem i have is there are no 4wd light turning on in my VIC (before and after a swaped the red and black plugs)... any thoughts? bad switch?
I currently have two Selec-Trac bezels for sale, $25 shipped a piece.
Here's a good visual for those of you unsure of the different input lengths. From the left, I have a 1.55" input from a 249, a .840" input from a 231, and finally a .750" input from a 242. They are all 23 spline shafts with the old style gear cut and they are all three interchangeable between each case.
A word of caution to those who attempt installing a .750" input in place of a .840" input: If you look closely at the center (.840") input, you'll see the upper most wear ring on the input. This is where the transmission output seal rides on the input shaft. As you can see, it's not very far from the edge of the shaft (approximately 3/10ths of an inch). If you attempt this swap, I recommend sealing the transmission and transfer case surfaces with Ultra Black or Gray RTV. I recommend this if your rig sees any deep mud or water anyways to keep sediment from ruining the transfer case and transmission seals.
Alright so I figured out how to wire up the 2 prong sensor from the 231 with the 4 prong wires from the 249. It's a lot simpler than you may think.
Alright so first off, you have to disconnect the red plugs behind the VIC and connect the black ones as the original writeup describes. All this action does is interpret the signal from the sensor differently. When the red plugs are connected (with the 249) the signal is interpreted as "4wd Lo". And when the black ones are connected it interprets the signal as "2wd", "Full-Time" and "Part-Time". Now when I say the sensor sends a signal, it's not really a signal, all it's doing is completing a existing circuit.
Alright so first you'll have to cut the 4 prong harness off and strip the 4 wires so you can do some splicing. then you'll have to connect the two wires you see in the first picture. Just twist them together for now. What this does is completes the circuit telling the VIC that you are in 2wd. the rear tires should be lit up on the VIC.
NOTE: I am unable to tell you the colors of these wires as...I'm colorblind, I was surprised I was able to figure this out as wiring, as you can imagine, is quite difficult for me.
So now cut the exposed wire completely that you see in the first picture...the one all the way to the right. You wont be using this. This wire is for the 242's "Full-Time" feature.
So now, while looking at the first picture, if you were to connect the all three wires the VIC would think you are in "4wd Part-time". So all the sensor really does is connect these three wires.
So splice the two wires from the 231 harness to the 2 wires you now have. See second picture.
NOTE: it does not matter which wires you use from the 231 harness because it's just jumping the wires together when the sensor is activated.
Now you're done test it with the sensor connected and when you depress the button on the sensor it should be in "part time" and when you release the button it should be in 2wd.
looking to do this t-case swap on a 96 v8...should have the 249, since that is what everything i have found says. its a v8 not sure what size, guessing 5.2...im trading my 2k pos bravada for it...this guy thought it was a good buy sold my 94 yj, and 96 xj, still kicking myself for it, to buy it...tired of beating my head against the wall when the damn car keeps stalling after being run for an hr...anyway, I want to do the swap so I am not running in 4wd all the time, $3.50+ a gallon would like to save some cash...so what years in the t-cases should i be looking for? I found one out of a 99...pretty much all i could find...but i am not 100% sure...i get lost in a lot of the specs, after reading so many threads they all run together...the t-case out of a zj is the same deal, but with the v8 and i6 what kind of swaps in the tcase will i have to make? help, what kinda donor do i need to look for to make this as painless as possible?
You won't gain any fuel mileage, so if that's your only motive for this swap then forget it. However if the VC is locked up (which it almost certainly will be), then swapping transfer cases is a good option.
A '99 will not work unless it is from an XJ and it has the speedometer provision. You want a 96-98 242 and will need to address the rear drive shaft only, or if you get lucky enough and find a 93-95 ZJ 242 with the .840 input shaft and internal rear slip yoke it will be a direct swap.