Transfer case swap NP249 to NP231 - JeepForum.com
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Unread 03-31-2014, 12:55 AM   #1
WildTornado77
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1995 ZJ 
 
Join Date: Aug 2012
Location: Jewett City, ct
Posts: 135
Transfer case swap NP249 to NP231

I bought a used transfer case out of an XJ 23 spline short input shaft. What troubles me is that the 231 output rear shaft seam slightly longer with external slip yoke, while my stock 249 has internal slip yoke. I believe the 231 is 96 and newer and the stock 249 is 95 so I can swap input shafts with no issue but the rear output?

Do I go and find a 96 and newer rear drive shaft out of a ZJ/XJ or can I swap rear output shafts and housings??

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Unread 04-04-2014, 03:12 AM   #2
WildTornado77
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Can anyone give any advice at all??
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Unread 04-11-2014, 12:02 AM   #3
WildTornado77
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bump update
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Unread 04-20-2014, 08:20 PM   #4
WildTornado77
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I am also rebuilding front differential, drive shafts, possible rear differential also.
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Unread 04-22-2014, 12:14 PM   #5
WildTornado77
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Here are a pic updates of my project.
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Unread 04-24-2014, 06:34 AM   #6
WildTornado77
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Here are update pics.
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Unread 04-25-2014, 11:39 PM   #7
WildTornado77
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Painting parts, Differential cover & front drive shaft parts.
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Unread 06-06-2014, 11:45 PM   #8
WildTornado77
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UPDATE finished dis-assembling front axle and uninstalled 249 transfer case, had to swap input shafts for 231 transfer case.
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Unread 06-12-2014, 10:35 PM   #9
WildTornado77
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Here are some more photos. Drilled and tapped for temp sensor for transfer case and front diff. Assembled transfer case but front yoke. torqued once and going to recheck. installed front diff also waiting on sender piece of guage to close front diff.
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Unread 06-18-2014, 12:29 AM   #10
WildTornado77
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Got my axle temp gauges today and I am going to have to run without vic info. Can not find a sensor that works unless I jury rig vacuum system out of XJ.
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Unread 06-22-2014, 11:26 AM   #11
WildTornado77
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Got my driveshaft for my rear sye set up and found a sensor that may work for my ZJ 231 transfer case.
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Unread 06-29-2014, 03:30 PM   #12
WildTornado77
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Here are some pics of the painting I have done.
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Unread 07-12-2014, 11:55 PM   #13
WildTornado77
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I am having issue with transfer case can not find 2H.
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Unread 07-20-2014, 10:11 AM   #14
WildTornado77
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Here is how i screwed up after swapping input shafts on transfer case 231.

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notice the red circle around the pin. Fork is installed upside down.

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notice its new/correct location
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