Transfer Case Swap Info NP249->NP231 & NP242 - Page 8 - JeepForum.com
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Unread 06-16-2010, 09:24 AM   #106
jlipka98zj
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1998 ZJ 
 
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Quote:
Originally Posted by JrMechanic View Post
96+ V8 ZJ's are known as the easiest swap as 96-98 4.0/Selec-Trac combos are very common, and they both share the .840" input shaft.
LOL! Yeah, unless you live in BFE (aka Wyoming). Between the two decent-sized junkyards we have around here, there is exactly ONE 96-98 ZJ in them and it's a limited so it has the 249.

Which really sucks because this write-up has renewed my interest in doing this swap. And if I can find a 242 out of 96-98 ZJ, sounds like it'd be pretty damned easy, too.

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Unread 06-28-2010, 05:24 PM   #107
x91j
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question. if i have a 1995 zj with a 4.0. and the man date is 12-94. what tcase should i use and what are my steps needed to find the right tcase?
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Unread 07-09-2010, 09:36 PM   #108
csouers
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Okay. Have both cases torn down. The 249 input and planetary set WILL NOT work in the 242. The annulus gears have a different cut. The input shafts are the same spline count and width, but with the 249 input being about 1/4" longer than the 242.

249 - 96 ZJ 44re
242 - 92 xj aw4

Am I screwed? There's no way it could work with out drilling a hole for the rubber plug and tapping a hole to operate the mode switch.
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1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
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Unread 07-10-2010, 07:33 AM   #109
JrMechanic
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The mode switch is a non issue, unless it is really that important to you. If you disassembled the case by removing the roll pin that holds the shift rail in, then you will want to drill a hole to reinstall the pin. If not, don't even worry about it.
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Want to swap an NP242 or NP231 into your ZJ? Here's how:
http://www.jeepforum.com/forum/f13/n...pdated-685644/
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Unread 07-10-2010, 10:34 AM   #110
csouers
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Quote:
Originally Posted by JrMechanic View Post
The mode switch is a non issue, unless it is really that important to you. If you disassembled the case by removing the roll pin that holds the shift rail in, then you will want to drill a hole to reinstall the pin. If not, don't even worry about it.
It looks like we're gonna drill the hole for the rollpin. The mode switch will work fine, because the back half of the 242 (which we're using) has the hole for how it's supposed to be.

The place where the shift rail sits, in the 242 is sleeved, where on the 249, it's not. Is this going to cause a problem with that little bit of play?
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1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

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Unread 07-10-2010, 02:19 PM   #111
EBT531
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Dont suppose anyone has the part number for a 231 shift indicator sensor? I understand the one from my 249 wont work, but I hate to go to a stealership for the part unless I have to. Thanks!
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1998 5.9ZJ, 231 TC w/SYE, IRO 4.5" Lift, IRO Adjustable CA's, Bilstien shocks, IRO Sliders, MVC Truss Rear, High Angle Driveline Front and rear shafts, 4.56 gears
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Unread 07-11-2010, 03:43 PM   #112
EBT531
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Ok did the 249/231 swap today. Everything went smooth except the shift linkage.

Is the shorter bar you describe, is it the one from the transfercase to the linkage? Or the bar coming down from the shifter itself?

I tried to do the adjustment you listed which allows 4LO no problem. But I cant get 2wd since as the linkage moves forward it strikes a bolt on the transmission as if its to long. I'm assuming this is the bar you state is shorter for a 231???

Edit: I think I found the part number for the shorter linkage. 5207 8116 seems to be right. Anyone know for sure?

Still cant find the 4wd switch. Seems like the ones I see are "vacuum activated" which I dont think will work for me. Anyone?
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1998 5.9ZJ, 231 TC w/SYE, IRO 4.5" Lift, IRO Adjustable CA's, Bilstien shocks, IRO Sliders, MVC Truss Rear, High Angle Driveline Front and rear shafts, 4.56 gears

Last edited by EBT531; 07-12-2010 at 05:30 PM..
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Unread 07-12-2010, 05:31 PM   #113
EBT531
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bump
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1998 5.9ZJ, 231 TC w/SYE, IRO 4.5" Lift, IRO Adjustable CA's, Bilstien shocks, IRO Sliders, MVC Truss Rear, High Angle Driveline Front and rear shafts, 4.56 gears
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Unread 07-12-2010, 07:15 PM   #114
csouers
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Quote:
Originally Posted by EBT531 View Post
Ok did the 249/231 swap today. Everything went smooth except the shift linkage.

Is the shorter bar you describe, is it the one from the transfercase to the linkage? Or the bar coming down from the shifter itself?

I tried to do the adjustment you listed which allows 4LO no problem. But I cant get 2wd since as the linkage moves forward it strikes a bolt on the transmission as if its to long. I'm assuming this is the bar you state is shorter for a 231???

Edit: I think I found the part number for the shorter linkage. 5207 8116 seems to be right. Anyone know for sure?

Still cant find the 4wd switch. Seems like the ones I see are "vacuum activated" which I dont think will work for me. Anyone?
Nope not vacuum activated. Ours are made with a little pintle that goes in and out. I slides on the shift mechanism inside of the case.
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1998 Bright Platinum ZJ 5.9 Limited - 5.9l, 46RE, NV-242, D30/44a (Trac-Loc) w/3.73s - The DD
1999 White XJ Sport - 4.0l, AW4, NP-231, D30/8.25 w/3.55s - The Rig

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Unread 07-14-2010, 02:44 PM   #115
EBT531
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Ok I found the correct switch for a 231 is part # J8134473 BUT the switch has 2 prong plug and my GC has a 4 wire plug. Has anyone successfully wired a 231 after pulling a 249??
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1998 5.9ZJ, 231 TC w/SYE, IRO 4.5" Lift, IRO Adjustable CA's, Bilstien shocks, IRO Sliders, MVC Truss Rear, High Angle Driveline Front and rear shafts, 4.56 gears
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Unread 07-20-2010, 08:39 AM   #116
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Ok, Jr. Guess what? Yep, you guessed it; more dumb specific questions.

First off, I have a '95 ZJ Limited with a 5.2L V-8/auto trans/249 (full-time 4WD). What would be my best (and by best, I mean easiest) swap, the 242 or the 231? I don't really care one way or the other about having 4 part time AND 4 full time. The 4HI, 4LO, N, and 2H is good enough for my purposes. I'm mainly looking for the most direct, bolt-up swap.

If I understand everything correctly, my best bet would be a 231 out of a 94.5 or newer TJ, YJ, GC, or C, adjusting the linkage, swapping the VIC connectors and bezel, and doing a few burnouts. Am I correct?

Brian
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Unread 07-20-2010, 02:18 PM   #117
Freddycrazy
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Hey everybody. Im replacing my Tcase, of course, and I was going through this whole post and I just don't seem to find the exact answer to my question. I have a 1997 Grand Cherokee with I6 so it's a 242 and I just wanted to know if a Tcase out of a 1996 Jeep Cherokee Sport I6 in which I do believe is a 231, would fit my 1997 or would any modifications have to be done. They're both 6cylinders but one is a Grand Cherokee and the other a Cherokee sport. Im new to the jeep world but have been gearing for a long time. Thanks
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Unread 08-02-2010, 10:10 AM   #118
outlawjeep
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Quote:
Originally Posted by EBT531 View Post
Ok I found the correct switch for a 231 is part # J8134473 BUT the switch has 2 prong plug and my GC has a 4 wire plug. Has anyone successfully wired a 231 after pulling a 249??
Did this ever get answered? I am getting ready to do the swap this weekend and wanted to know. I have the wiring harness from the XJ as well so can I just cut and splice the wires and make it work or will I not be able to see when I put it in 4wd?


Ray
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Unread 08-02-2010, 10:32 AM   #119
EBT531
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Quote:
Originally Posted by outlawjeep View Post
Did this ever get answered? I am getting ready to do the swap this weekend and wanted to know. I have the wiring harness from the XJ as well so can I just cut and splice the wires and make it work or will I not be able to see when I put it in 4wd?


Ray
Never did get an answer. Right now I have the switch in there just to fill the hole. I go by feel and with a locker in the front its pretty obvious when I am in 4wd
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1998 5.9ZJ, 231 TC w/SYE, IRO 4.5" Lift, IRO Adjustable CA's, Bilstien shocks, IRO Sliders, MVC Truss Rear, High Angle Driveline Front and rear shafts, 4.56 gears
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Unread 08-02-2010, 03:32 PM   #120
JrMechanic
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I don't have any experience wiring a two prong plug into a 4 wire switch. I'm sure it wouldn't be difficult, I'll have to find a wiring schematic for each to find out though.

Is it really a big deal though? You already have the shift lever telling you what gear you're in.
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Want to swap an NP242 or NP231 into your ZJ? Here's how:
http://www.jeepforum.com/forum/f13/n...pdated-685644/
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