Question about 249 -> 242 swap - JeepForum.com
 
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post #1 of 14 Old 03-06-2021, 12:03 PM Thread Starter
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Question about 249 -> 242 swap

i have a question for all of you guys out there, im a bit of a noob to jeeping but im learning. i got a 97 jeep GC zj with the 4.0 in it. i am locking to change the transfercase cuz my 249 has a bad vc in it. on fb i foud a free 242 tc with a sticker that reads 242 AMC date is 6 20 88. it was paired up to a transmtion with
model No 30-40LE produced by asiin WS co made in japan. serial 88D R 51829 to me it doesent sound like that was sitting inside a jeep but the guy giving it away said that he bought it from a guy with a 95 gc and the transmition was mated to a 4.0 I6 so im wondering.

correct me if im wrong but the 87-93 242 and the 94-> 242 are slightly different? so they are not just swap input shaft and put in. also on pictures of the transfer case 3 things stick out to me 1 no gear select sensor, 2 the speed sensor locks wierd. 3 the output schaft to the rear has a metal sleve on it lite the HD case but it is not a HD case.

ill post pictures of the tf and the transmition and what im wondering is. is it at all possible to fit this 242 in my zj with a 249j tf?

well i could not post links cuz im new to forum

so the question again is this case even compatible with my transmition and drivetrain? or do i have to make big modifications to it? i rather not

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post #2 of 14 Old 03-06-2021, 03:02 PM
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You can swap in an older version of a 242 if you use the front case half, input gear and front planetary from your 249. Drill the access hole for the 242 shift rail dowel pin.
All other parts will be used from the 242. I've done a similar case half swap, used the 249 front case from my 5.9, and all the other parts from the 1990 XJ.

Speed sensor is different because Jeeps used a mechanical (cable- operated) speedometer until 1991. There are different output shaft types.

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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #3 of 14 Old 03-07-2021, 02:14 AM Thread Starter
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Quote:
Originally Posted by Timo_90xj View Post
You can swap in an older version of a 242 if you use the front case half, input gear and front planetary from your 249. Drill the access hole for the 242 shift rail dowel pin.
All other parts will be used from the 242. I've done a similar case half swap, used the 249 front case from my 5.9, and all the other parts from the 1990 XJ.

Speed sensor is different because Jeeps used a mechanical (cable- operated) speedometer until 1991. There are different output shaft types.
can i fit my speed sensor from the 249 into the 242 side is the old mechanical speed sensor hole compatible with the 249 speedsensor? will the rear output shaft fit my rear shaft?
ok do you know if there is a video or pictured descrioption of this swap anywhere?
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post #4 of 14 Old 03-07-2021, 03:58 AM
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Originally Posted by IdCrisis View Post
can i fit my speed sensor from the 249 into the 242 side is the old mechanical speed sensor hole compatible with the 249 speedsensor?
Newer electric- speedometer gear & housings are a direct swap.

Quote:
will the rear output shaft fit my rear shaft?
You really need to check that out, but usually they use the same splines. Worst case scenario is you get a rear DS from a 242-equipped ZJ.

Quote:
ok do you know if there is a video or pictured descrioption of this swap anywhere?
Use the factory service manual, download from jeepslimited. These transfer cases are fairly easy to work with, 242 has a couple extra steps but it's not really that hard to assemble.
I disassembled my 242 at the end of last summer, it literally took about 5 minutes from start to end.

All this being said, it's much easier to swap in a 242 from the same vintage Jeep XJ or ZJ that you have. I did what I did due to shortage of used suitable 242s around here - and for the fact I already had an extra one in the garage.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #5 of 14 Old 03-07-2021, 06:11 AM Thread Starter
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Quote:
Originally Posted by Timo_90xj View Post
Newer electric- speedometer gear & housings are a direct swap.

You really need to check that out, but usually they use the same splines. Worst case scenario is you get a rear DS from a 242-equipped ZJ.

Use the factory service manual, download from jeepslimited. These transfer cases are fairly easy to work with, 242 has a couple extra steps but it's not really that hard to assemble.
I disassembled my 242 at the end of last summer, it literally took about 5 minutes from start to end.

All this being said, it's much easier to swap in a 242 from the same vintage Jeep XJ or ZJ that you have. I did what I did due to shortage of used suitable 242s around here - and for the fact I already had an extra one in the garage.
ok sweet ill lock around for tc from a zj witch is a direct swap and use the free one in worst case, i was and picked it up today and got the tc , the transmition and a rear outputshaft and housing from a 231 i dont know if the 231 fits in the 242 but it could be good to have or sell. everything i got for free so free is always best XD found out that the spedo sensor seems to have the same mounting hardware.

only thing that struck me is that the gear shift inicator sits on the rear of the 242 tf but i will recall that the indicator sits at the front one on the 249?
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post #6 of 14 Old 04-06-2021, 07:50 AM Thread Starter
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ok on friday ill pick up a tc from 1998 it is today sitting inside a jeep zj 1998 4.0 laredo. the driveshaft to the rear have gotten damaged by the car scrapping place so i cant take that, my question now is how do i know if i need to shorten my rear driveshaft? im guessing the tf will just be a direct swap no need to change the inputshaft because they sit in the same vehicle as im putting it in (donor 1998 4.0 laredo mine a 1997 4.0 limited.) im gonna try with the driveshaft from mine otherwise ill have it cut and rebalanced but how mutch do i need to cut?
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post #7 of 14 Old 04-06-2021, 07:54 AM Thread Starter
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Originally Posted by IdCrisis View Post
ok on friday ill pick up a tc from 1998 it is today sitting inside a jeep zj 1998 4.0 laredo. the driveshaft to the rear have gotten damaged by the car scrapping place so i cant take that, my question now is how do i know if i need to shorten my rear driveshaft? im guessing the tf will just be a direct swap no need to change the inputshaft because they sit in the same vehicle as im putting it in (donor 1998 4.0 laredo mine a 1997 4.0 limited.) im gonna try with the driveshaft from mine otherwise ill have it cut and rebalanced but how mutch do i need to cut?
and if i whant to find a rear driveshaft from a jeep xj that will fit mine zj what length should i loock for? and how do u measure the length?
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post #8 of 14 Old 04-06-2021, 08:22 AM
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XJ rear driveshafts will not work, they are WAY too short. If your current TC and the replacement both use the same style slip joint, it's possible you current rear DS works just fine. I honestly never remember which TCs use external and which use internal slip yoke - I've had a slip yoke eliminator in my Jeeps since 2007.

Measure how much slip yoke engagement you have at ride height when the DS is bolted in, if it's less than 1.5" it's less than ideal.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #9 of 14 Old 04-06-2021, 02:13 PM Thread Starter
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Quote:
Originally Posted by Timo_90xj View Post
XJ rear driveshafts will not work, they are WAY too short. If your current TC and the replacement both use the same style slip joint, it's possible you current rear DS works just fine. I honestly never remember which TCs use external and which use internal slip yoke - I've had a slip yoke eliminator in my Jeeps since 2007.

Measure how much slip yoke engagement you have at ride height when the DS is bolted in, if it's less than 1.5" it's less than ideal.
ok thank you ill check in worst case i have to buy budget boost lift pucks to maby get the DS to fit better?
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post #10 of 14 Old 04-06-2021, 05:39 PM
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Question about 249 -> 242 swap

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Originally Posted by IdCrisis View Post
ok thank you ill check in worst case i have to buy budget boost lift pucks to maby get the DS to fit better?

A shop will correct the length for around 100 bucks.
The place near me does it same day.
I had mine shortened because the 242 was maybe an inch longer than the 249.

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post #11 of 14 Old 04-07-2021, 10:23 AM Thread Starter
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Originally Posted by PolkaPower View Post
A shop will correct the length for around 100 bucks.
The place near me does it same day.
I had mine shortened because the 242 was maybe an inch longer than the 249.

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XD i live in sweden so fixing driveshaft here is starting 2000 sek witch is 240 usd if its simple job but up to 500 usd if its harder job XD
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post #12 of 14 Old 04-07-2021, 11:24 AM
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XD i live in sweden so fixing driveshaft here is starting 2000 sek witch is 240 usd if its simple job but up to 500 usd if its harder job XD
Last time I had to have a DS retubed after I hit it on a rock and bent it, cost me ~350 including balancing (in Helsinki region). Shortening a tube is around 150-200. Used to be way cheaper here, but prices skyrocketed ~5 years ago after a couple local shops went out of business.

1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...


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1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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post #13 of 14 Old 04-07-2021, 04:44 PM
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Question about 249 -> 242 swap

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Originally Posted by IdCrisis View Post
XD i live in sweden so fixing driveshaft here is starting 2000 sek witch is 240 usd if its simple job but up to 500 usd if its harder job XD

Dang, take that money and buy tools instead to do it yourself. I hate being at the shops mercy. Ironically I am in that position currently here in Japan. I have room for a pop up tent between typhoons lol.

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post #14 of 14 Old 04-08-2021, 12:43 PM Thread Starter
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Originally Posted by PolkaPower View Post
Dang, take that money and buy tools instead to do it yourself. I hate being at the shops mercy. Ironically I am in that position currently here in Japan. I have room for a pop up tent between typhoons lol.

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i would but i dont dare cuz if the driveshaft snaps while on highway im screwed
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