I just went through the 249 --> 242 swap.
I started with a 249 (1998), that was skipping at low speed turns. When I opened up the 249, everything looked pristine, so I assumed the VC was the bad part. I decided to go with the 242 swap to save money.
I found a 242 (1997, supposedly) on craigslist, and when I picked it up, all the bearings, chain, etc, were more worn than my 249, but everyone says they last forever, so I just switched out some of the bearings and swapped the inputs. Also, the output shaft was a little long so...I just cut it short and it barely fits the rear drive shaft:-D...was that okay to do?
1. The shift tab I got (the part of the linkage directly attached to the tcase with one rectangular hole and one normal hole) is too long; it seems that the guy had given me a 249 shift tab with my 242. Does anyone know the distance between the holes so I can just drill it out? Right now the car only goes 4ft, N, 4Lo.
2. When I put the car in 4lo, it makes quite a bit of noise and jumps/skips when I turn, just like when I had the 249 in it. When I'm in 4FT, it makes less noise and doesn't skip. Is there a part in the tcase I have that's broken? I know you guys say it takes a bit of time to wear into the 4wd if it hasn't been used, but the 4ft is fine...
Any help is greatly appreciated! I wonder if I'm going to have to get another tcase:-/.