Transfer Case Swap Info NP249->NP231 & NP242 - Page 60 - JeepForum.com
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Unread 11-09-2011, 04:44 PM   #886
sskilla
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1995 ZJ 
 
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yeah if you can find it

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Unread 11-09-2011, 05:35 PM   #887
onevision
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LOL Don't get me wrong, I'm not saying that the 249 is the end all transfer cases - or even that it's necessarily good. It does however perform well for what is was designed to do, but not really designed to last a long time. Personally I've never had any problem with the viscous coupler, but eventually that chain is going to stretch and cause a lot of problems.

If you have a Dana 35 in the rear, I'd say that is going to be a pretty weak link in your setup, but if your not doing any hard wheeling then you may get by just fine with it. I will however limit what you can pull or put extra load on. The rear axles on 93-98 ZJ's suck though, since they have an aluminum differential housing (unless you happened to buy a ZJ from Canada). That limits what you can do with it - mainly adding a locker is not an option. You can beef up the 35 by putting in 4340 chromoly shafts, and that will help a lot with making it stronger, but the big performance boost is really in locking it.

Nice, you have a 5.2 with a 46 RH trans! Did you swap the transmission or did it come like that? I thought they only put the 46 in with the 5.9 editions. The 46 is a lot more heavy duty than the 42RE or the 44RE. Not sure on the 242, but I know the footprint is pretty close to the same. The 249 will swap out to the 231 without much fuss, so long as you get the J type 231.
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Unread 11-09-2011, 08:06 PM   #888
comptiger5000
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93 - 95 5.2s had the 46RH, 96 - 98 had the 44RE, and the 98 5.9 had the 46RE.

Also, only 96 - 98 V8s had the D44a, the others had an iron D35. The 44a isn't weak anyway, it just has a few flaws.
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Unread 11-09-2011, 11:52 PM   #889
RedneckZJ
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i have a 96 v8 zj with the 249. would a 96-98 zj with the 242 be a direct swap (including driveshafts). if not what would be needed for the swap?
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Unread 11-10-2011, 02:35 AM   #890
csouers
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Quote:
Originally Posted by RedneckZJ
i have a 96 v8 zj with the 249. would a 96-98 zj with the 242 be a direct swap (including driveshafts). if not what would be needed for the swap?
Depending on what rear end both Jeeps have, yes.
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Unread 11-10-2011, 10:30 AM   #891
MilanJeep
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Quote:
Originally Posted by RedneckZJ View Post
i have a 96 v8 zj with the 249. would a 96-98 zj with the 242 be a direct swap (including driveshafts). if not what would be needed for the swap?
Yes!
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Unread 11-10-2011, 07:51 PM   #892
kmm2736
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How long did take to rebuild the transfer case? I Plan on driving my ZJ this winter and cant afford to have off the road. I was thinking of finding a 242 and rebuilding and then picking a weekend and Busting it out.
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Unread 11-10-2011, 08:28 PM   #893
squazz
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Quote:
Originally Posted by kmm2736 View Post
How long did take to rebuild the transfer case? I Plan on driving my ZJ this winter and cant afford to have off the road. I was thinking of finding a 242 and rebuilding and then picking a weekend and Busting it out.
Couple hours just make sure you order proper size bearings I got my kit including chain at a fair price from eastcoastgearsupply.com



Am I right in thinking only V8's have to worrie about gear cut change?
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Unread 11-10-2011, 08:34 PM   #894
csouers
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Yup. As long as you have all the parts on hand, maybe 3-4 hours if you have never done it before. Cleaning everything takes the longest. Reassembly goes by quick.
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Unread 11-10-2011, 11:11 PM   #895
zachjf
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so whats the deal with the WJ 242's? I tried searching through the 60pgs of info here and searching the forums but couldn't come up with a definitive answer. I have a 98 5.9 that NEEDS a 242 but I can't find a nice, low mileage one out of a ZJ or an XJ right now. I have found a half dozen out of WJ's for next to nothing but that doesn't do me any good if its not a bolt in swap, can't have my rig down for days since its my only transportation
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Unread 11-11-2011, 08:59 AM   #896
KingtheZJ
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Quote:
Originally Posted by zachjf View Post
so whats the deal with the WJ 242's? I tried searching through the 60pgs of info here and searching the forums but couldn't come up with a definitive answer. I have a 98 5.9 that NEEDS a 242 but I can't find a nice, low mileage one out of a ZJ or an XJ right now. I have found a half dozen out of WJ's for next to nothing but that doesn't do me any good if its not a bolt in swap, can't have my rig down for days since its my only transportation
they have a different tailshaft that doesnt have the speedo gear output.
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Unread 11-11-2011, 09:45 AM   #897
comptiger5000
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^ Correct. WJs sense the speedo from the ABS tone rings, so they don't have a speedo sensor provision on the t-case. If you've got a dead 249 and need something to throw in, I've got the 105k mile 249 (VC still good) that came out of my 5.9 laying in my parents' garage. It's yours for the cost of shipping if you want it.
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Unread 11-11-2011, 11:17 AM   #898
onevision
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I think these two file will give anyone interested a lot of helpful information. They cover the complete disassembly and assembly of the 231, 242, and 249 transfer cases - as well as the 42RE, 44RE, and 46RE transmissions. I know it's been extremely helpful for me and my bible for the last 6 years. LOL

onevisionbeyond.com/jeep_manual/english/ezg_21.pdf
onevisionbeyond.com/jeep_manual/english/ezg_21a.pdf
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Unread 11-14-2011, 11:49 AM   #899
AngryVanilla
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I've been researching this for awhile now and have some questions... I have a 94 ZJ 5.2 w/ 249 TC... The build date on my Transfer Case is pre-92, i forget the actual date, but it was in 1992... So i have the old style gear cut, correct??? From my research i have found that i need a NP242 from a XJ w/ Transfer case build date of Pre-94.5, and i will have to swap my input shaft from my 249, correct???

Last question is, i have a NP242 Transfer Case i believe is from a TJ, im not sure though, and the build date is 2001 on the case... Is there anyway i can make this work??? Like buying a junk 249 post-94.5 build date, and swap the input shaft??? Or is it useless in my swap into a 94 ZJ???

Thanks
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Unread 11-14-2011, 07:41 PM   #900
4xclimb
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So how much are these 242's finished going for? PM messageing box is always full so I try this way....
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