Transfer Case Swap Info NP249->NP231 & NP242 - Page 5 - JeepForum.com
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Unread 02-07-2010, 01:59 PM   #61
highlyuncntered
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Well, I guess the .840" rule does apply for all GCs after 96. Swap went well, it dropped right in and the driveshaft fit the same too. Thanks for the help. Now I just have to mess with the 4wd switch.:

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Unread 03-01-2010, 11:11 PM   #62
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The part number for the revised transfer case linkage bearing (I see it as more of a bushing, it's the flat metal piece that mount to the body to support the shaft that goes from it to the transmission) is Mopar PN 52078135.
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Unread 03-02-2010, 08:18 AM   #63
rustynail
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Awesome write up.

It would be good to see info in there about drive shafts needing to swapped or lengthened/shortened. eg. If I pull a 242 from the wrecker will I also need the rear drive shaft since the 242 appears to have a different style output then what I have. Also do the 44a and 35 have the same u-joints, drive shaft type, length, etc.
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Unread 03-02-2010, 10:00 AM   #64
JrMechanic
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Quote:
Originally Posted by ZJ-Orvis View Post
Awesome write up.

It would be good to see info in there about drive shafts needing to swapped or lengthened/shortened. eg. If I pull a 242 from the wrecker will I also need the rear drive shaft since the 242 appears to have a different style output then what I have. Also do the 44a and 35 have the same u-joints, drive shaft type, length, etc.
I will add that information. FYI All external slip yoke 249, 231, and 242's have the same overall length (within 1/4" or so.) The same holds true for the external slip yoke style cases.

Only time you should have a problem with the drive shaft is swapping from an internal slip yoke case to an external slip yoke case (or vice versa.) The external slip yoke style requires a drive shaft that is around 1 1/8" shorter IIRC.
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Unread 03-06-2010, 10:36 PM   #65
AZjeepin1
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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 see you mention the measurements of the ZJ shaft, but can you tell me what the measurements from the XJ are, so I can pickup the correct TC?
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Unread 03-07-2010, 01:59 AM   #66
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Quote:
Originally Posted by ZJ-Orvis View Post
Awesome write up.

It would be good to see info in there about drive shafts needing to swapped or lengthened/shortened.
Straight from the FAQ. You can see that it is not so easy factoring the DS lengths. This should help everyone though.

http://www.jeepforum.com/forum/f197/...ml#post8630870
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Unread 03-07-2010, 10:32 AM   #67
JrMechanic
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Originally Posted by Virmagicus View Post
Straight from the FAQ. You can see that it is not so easy factoring the DS lengths. This should help everyone though.

http://www.jeepforum.com/forum/f197/...ml#post8630870
That doesn't have anything to do with the transfer case though (other than the external vs internal slip yoke.)
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Unread 03-10-2010, 11:56 AM   #68
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Awesome info. I am hoping to finish mine up tonight. I have gotten 2 wrong transfer case's from the salvage yard. I finally just got my money back and sent a buddy to pull the right one for me. I had him pull the driveshaft's just in case as well. Hopefully I will be able to see just how much of a tire smoker the 5.9 is sometime later tonight.
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Unread 03-11-2010, 08:49 AM   #69
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It is all together. I had to do a little modifying of the shift linkages to get it to go into 2wd. Couldn't be more happy with the swap.

Did our first smokey burnout sometime around 11:30 last night.
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Unread 04-07-2010, 11:20 PM   #70
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This is now on the to do list, btw so if I went to the JY if I pulled a 242 out of a 96-98 It would be a direct swap correct?
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Unread 04-08-2010, 08:52 AM   #71
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Oh darn I was hoping it would have info for the WJ swap! owell
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Unread 04-08-2010, 09:15 AM   #72
cttandy
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Quote:
Originally Posted by spencerk73 View Post
This is now on the to do list, btw so if I went to the JY if I pulled a 242 out of a 96-98 It would be a direct swap correct?
Should be, I pulled the rear drive shaft as a safety (they only wanted $20), but didnt need it.
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Unread 04-08-2010, 09:49 AM   #73
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Originally Posted by jclaudii View Post
Oh darn I was hoping it would have info for the WJ swap! owell
I am working on a write up for a 4.7l 247 to a 242j from a 4.0. I have a 2002 4.7 with a toasted 247 case. I could get the 242j all day long for under $100 but the 242HD (one that would be a direct fit) was over 100 miles away from me and was $400 + I would need the drive shaft from it for another $100.

I am digging into both cases this weekend to swap the input gears (so that it will mate properly with my 545rfe and the output main shaft along with the tail cone from the 247. This way, I should not need a different driveshaft as all the lengths and spline counts should match up. I will also be swapping the front yoke as the I have a u-joint style front ds and the 242 I bought has a cv style yoke.

I will be posting a new thread once the swap is complete with a write up. In the meantime, here is the thread I started when I first started thinking about doing this.

http://www.jeepforum.com/forum/f13/q...2-swap-996428/
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Unread 04-21-2010, 10:45 PM   #74
tednelson83
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ok, so are there any 242 cases that would be a direct swap into a 93 5.9 with a 249? if not, what would be my best bet? getting one from an XJ?
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Unread 04-22-2010, 09:53 AM   #75
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Originally Posted by tednelson83 View Post
ok, so are there any 242 cases that would be a direct swap into a 93 5.9 with a 249? if not, what would be my best bet? getting one from an XJ?
I actually just answered this exact same question for someone else in a PM, lol.

I have heard that the 242 was a factory option behind the 5.2 in something like 1994. I've never personally seen one, and if they do exist, the chances of finding the T case from one are pretty slim.

So no, there are no direct swaps for the 93-95 5.2L. Your best bet is to find a 242 out of an XJ with a build date of 1994.5 or older (from the T case not the Jeep.)
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