Transfer Case Swap Info NP249->NP231 & NP242 - Page 67 - JeepForum.com

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post #991 of 3301 Old 01-05-2012, 03:17 PM
jlipka98zj
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1998 ZJ 
 
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Quote:
Originally Posted by Freestyle713 View Post
I have a problem. I swapped my speedo gear but the speedometer doesnt work. The gears arent the same. I was going to just swap them but the shafts are different lengths. I tried tapping the shaft out of the gears but it didnt work. Anybody have a solution? I need the green gear in the black housing
Solution = spend the $30 and get the correct speedometer gear.

Short shaft is 93 & newer, long shaft 93 & older. Not interchangeable.


'98 5.9 Limited - Got some stuff done to it...
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post #992 of 3301 Old 01-05-2012, 03:19 PM
Freestyle713
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Quote:
Originally Posted by jlipka98zj View Post
Solution = spend the $30 and get the correct speedometer gear.

Short shaft is 93 & newer, long shaft 93 & older. Not interchangeable.
I fixed it. Just had to turn the housing 90 degrees.
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post #993 of 3301 Old 01-05-2012, 03:24 PM
jlipka98zj
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Originally Posted by Freestyle713 View Post
I fixed it. Just had to turn the housing 90 degrees.
That too. There should be numbers printed on the outside of your housing. Numbers like "33-36" and "37-39". When reinstalling the pickup, the range that contains the number of teeth on your speedometer gear must be rotated so it matches with a little dot on the transfer case (usually pointed straight down). Usually not a problem until someone installs a new gear after a lift/bigger tires, but they don't know this little tidbit.

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post #994 of 3301 Old 01-07-2012, 12:33 PM
E-rok
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I am sure this has been asked but honestly I read all 67 pages of this thread like 3 times and its making my head spin!

anyways, I have a 92 242 that I am putting in my 96. I know I need to do a front case swap as the 242 has a .750 input. I was thinking about just running it but I might as well do it right.

my main question is, does the 249 shift indicator work with the 242? I know the JY currently has a 97 ZJ with a 242 if I need to pull the sensor but if its the same part why bother.....

I thought about snagging the 242 off the ZJ but the 242 I have has the ISY so I dont have to do any driveline changes.

but anyways, my main question was about the shift indicator, if anyone can give me a quick answer so I dont have to sift thru 70 pages again lol
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post #995 of 3301 Old 01-07-2012, 03:36 PM
KingtheZJ
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Quote:
Originally Posted by E-rok View Post

my main question is, does the 249 shift indicator work with the 242? I know the JY currently has a 97 ZJ with a 242 if I need to pull the sensor but if its the same part why bother.....
the 249 shift indicator will not work in a 92 case. ive done a front half swap. its not too bad. the worst part is getting the shift fork assemble out of the 242 front. you can drill out the roll pin from the low range fork, but i recommend just fording it out like it did. small prybar and large flat head and it sould come out. its a little tricky.

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post #996 of 3301 Old 01-07-2012, 07:12 PM
E-rok
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Originally Posted by KingtheZJ View Post
the 249 shift indicator will not work in a 92 case. ive done a front half swap. its not too bad. the worst part is getting the shift fork assemble out of the 242 front. you can drill out the roll pin from the low range fork, but i recommend just fording it out like it did. small prybar and large flat head and it sould come out. its a little tricky.
ahh I was hoping I could put it in the rear in place of the 242 shifter and put a plug where it was on the 249 front, oh well. Not a huge issue as I was thinking about putting a trans temp gauge and a GPS where the VIC is. we'll see...

not worried about the front case swap, seems pretty straightforward and its not my first time working on jeeps lol

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post #997 of 3301 Old 01-10-2012, 05:49 AM
acfortier
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Thinking about doing this swap also. The NP249 is making an awful noise (at least, what I think is coming from the transfer case) so I'm going to swap it out. Thought about going with a 242, but was unsure about how much work it'd be after reading this thread post.

Since my ZJ is model year 1996 but build date in 1995, will I still have the ".840 input shaft with 23 spline? And for me to swap a 242 I can simply get one from the same years (96 - 98) and it will contain the correct shaft and spline?
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post #998 of 3301 Old 01-10-2012, 08:21 AM
comptiger5000
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Yes, a 96 should have the .840" input regardless of which year it was built.
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post #999 of 3301 Old 01-10-2012, 11:29 PM
swillett
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so just to clarify:

In my '93 ZJ I have a 249 that has a bad VC.

I want to do this as painlessly as possible.

Am I correct in saying that I can dig up any 242 and bolt on the front half of my old (and busted) 249 and have a compatible t case?

Will I have to use the driveshaft that was originally attached to the donor 242?

Last edited by swillett; 01-11-2012 at 08:41 AM.
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post #1000 of 3301 Old 01-12-2012, 08:16 PM
E-rok
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Quote:
Originally Posted by swillett View Post
so just to clarify:

In my '93 ZJ I have a 249 that has a bad VC.

I want to do this as painlessly as possible.

Am I correct in saying that I can dig up any 242 and bolt on the front half of my old (and busted) 249 and have a compatible t case?

Will I have to use the driveshaft that was originally attached to the donor 242?
you need an old gear cut (mid 94 or older) 242 for your 249 input shaft to swap right in.

since you can find 242's in older xj's all day, it shouldnt be hard to find one.

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post #1001 of 3301 Old 01-12-2012, 08:18 PM
E-rok
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ok so I grabbed a 242 shift sensor off a 98, it was in the front of the case like where it is on my 249, opposed to my '92 242 which has it in the back half of the case. I assume since I am doing the front case swap, ill use the port on the 249 front case and either plug the back hole or leave the sensor in unplugged?

anyways, I looked at the shifter mechanisms on the 242 ZJ and compared it to a 249 one and the only thing different is the tab on the TC so there is no need to swap anything else. Im sure thats been covered a bunch but I see it asked alot.

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post #1002 of 3301 Old 01-12-2012, 08:54 PM
E-rok
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ok quick question

I am looking to order a rebuild kit for the 242, its a 92 and since I am using my 96 front case, do I use the 95+ rebuild kit? any other changes besides the input bearing size?

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post #1003 of 3301 Old 01-12-2012, 09:10 PM
acfortier
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By shifter mechanisms, do you mean the linkage? Are you saying that the linkage for a NP242 and a NP249 are the same other than a tab on the TC?

I don't really want to have to deal with messing with the linkage, so I've been trying to search local junkyards for linkage included, but haven't been having any luck...
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post #1004 of 3301 Old 01-13-2012, 12:43 AM
swillett
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Quote:
Originally Posted by E-rok View Post
you need an old gear cut (mid 94 or older) 242 for your 249 input shaft to swap right in.

since you can find 242's in older xj's all day, it shouldnt be hard to find one.

I know that the gear cut on the input shafts changed mid '94, but I also read that the front case halves are interchangeable between 242's and 249's.

If this is the case then i wouldn't have to worry about switching input shafts, i would just swap out the whole case half.

right???
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post #1005 of 3301 Old 01-14-2012, 11:35 PM
93zjer
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Just finished my 249 to 231 swap!
It would have been tough without this thread, thanks!
Donor was a 94 ZJ IL-6/42RE.
My jeep is a 93 ZJ IL-6/AW4.
I had to swap the inputs.

Retaining ring pliers (not snap ring) are a must as well as a big pipe wrench to hold the yoke.
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