Transfer Case Swap Info NP249->NP231 & NP242 - Page 68 - JeepForum.com
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Unread 01-16-2012, 09:56 AM   #1006
Sublime69
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I have reading this reading thread because i want to get rid of my 249. I am just confused on which tc i should look for in the junk yard. I have a 93/AW4/249. Which is the best tc to get and is there one that is just a straight bolt in? Or am i defiantly going to have to swap the inputs?

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Unread 01-16-2012, 10:22 AM   #1007
comptiger5000
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Being that you have a 4.0, a 242 from a 93 - 95 4.0 ZJ, or 92 - 95 4.0 XJ should bolt right in (I'm not positive that those were all the same input, but I'm pretty sure they are).
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Unread 01-16-2012, 10:43 AM   #1008
Sublime69
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Thanks..can anyone else verify this?
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Unread 01-19-2012, 05:52 AM   #1009
Berti
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Hello All,
I'm Berti from Hungary and just finished the swap on 96 ZJ. I took a NP242 from 90 with a 0.750 input. The old 249 had a 0.840 input, and after measuring the position of the output seal, I've decided not to change the inputs. Just to be sure, before installation, I disiassembled the 242, cleaned, renewed the seals. The swap went well, I could adjust the shift linkage, speedo is also working, the only problem is, that cable for the shift indicator is too short. But I can live without a properly working VIC. My decision was right, it is not loosing oil from the transmission output seal The Jeep drives great in 2WD, all the noises are disappeared!
Kind Regards,
Berti
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Unread 01-19-2012, 11:55 AM   #1010
bullitt_9350
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Read through this thread, did some reading on Novak's knowledge base and just want to confirm - 231 from a 92 XJ should have the same input as my 96 249?

96-98 249 should have medium input shaft.
Novak says 231s behind AW4s after 1990 with 23 spline are medium length.
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Unread 01-22-2012, 07:12 PM   #1011
steeleman3
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So I was gonna head out this weekend and pick up a 231 TC to swap for my 249. I have a 93 so I'll have to swap my input shaft, but my tranny has been actin up too so I was wondering if I could pull a 46rh and 231 and just swap in the whole thing. Is this a possibility or has anyone done such thing?
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Unread 01-23-2012, 10:50 PM   #1012
steeleman3
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Went to U-Pull and Pay today and grabbed a 231 out of a 93 xj and a 249 out of a 93 zj. My 93 is a DD and can't have the downtime of swapping the input shafts so I pulled the same 249 out of another zj for the input shaft. No pics, yet. Should be tearing them both down and geting the 231 ready to throw in the zj in the next few days. I'll try and get pics. Pretty easy taking them out, now its just a matter of swapping inputs and getting the new one cleaned up. Anyone know how much play is supposed to be in the TC from the input to the front output? Seems like theres a bit of excess play in the both the new ones.
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Unread 01-24-2012, 08:17 PM   #1013
2GPS4ME
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231 Question:

I have a match made in heaven. Vehicle is '98 Limited, and I'm swapping in a 231 from an '04 TJ. Identical input shafts, overall lengths, etc. However.....

Which lever (the one mounted to the transfer case) do I use on the 231 with the stock linkage in the ZJ? The long (249) or the short (231)?
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Unread 01-24-2012, 09:05 PM   #1014
comptiger5000
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You need the linkage lever that's already on the 231 (should be shorter than the 249 one).
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Unread 01-24-2012, 09:07 PM   #1015
2GPS4ME
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Quote:
Originally Posted by comptiger5000 View Post
You need the linkage lever that's already on the 231 (should be shorter than the 249 one).
Perfect, thanks a bunch!
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Unread 01-26-2012, 11:56 PM   #1016
Taz360ZJ
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Just an FYI i helped pioneer this swap 10 years back over on JU with my '93 V8 & 231. I did the 242 swap on my 5.9 2 weeks after i bought it in Feb '10, and Nov last year i swapped an older style non exposed output '95 ZJ 231 in it so the VIC would work correctly. Ended up swapping a '98 249 low range input in it to make it work, and hacking an inch out of my stock shift rod.
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Unread 01-28-2012, 02:43 PM   #1017
E-rok
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ended up pulling a 242 out of a 96 ZJ today because I really didnt feel like doing a front case swap on my 92, I also got the driveshaft so hopefully it should fit right up. it had a D35 so hopefully that added length wont be an issue.

anyways, the donor had 3.55 gears, and I have 3.73's and 31's. would leaving the 3.55 speedo gear and sensor essentially bring me back to stock settings since I have 31's? furthermore, did Jeep even use different gear and sensors for the two different gearsets or did they just run the same one since theyre pretty close?
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Unread 01-28-2012, 03:27 PM   #1018
Taz360ZJ
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They used different speedo gears.
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Unread 01-28-2012, 03:41 PM   #1019
E-rok
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yea thats what I just read. I dont have the swap the gear on the shaft, just the sensor one, right?
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Unread 01-28-2012, 03:55 PM   #1020
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Quote:
Originally Posted by E-rok View Post
ended up pulling a 242 out of a 96 ZJ today because I really didnt feel like doing a front case swap on my 92, I also got the driveshaft so hopefully it should fit right up. it had a D35 so hopefully that added length wont be an issue.

anyways, the donor had 3.55 gears, and I have 3.73's and 31's. would leaving the 3.55 speedo gear and sensor essentially bring me back to stock settings since I have 31's? furthermore, did Jeep even use different gear and sensors for the two different gearsets or did they just run the same one since theyre pretty close?
Yes, the stock gear used with 3.55's is perfect for 31's and 3.73's. I have the same combination and at 65 MPH I read 66 on my GPS.
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