I am planning on swapping my 249 out for a 242. I just read the other day (forget where) that in 94 or something they changed the bearing size in the 242 so my (98) input shaft will not work in pre 94 models or something like that. anyone know if this is true and if so which years can I use (94 and later or anything after 94)?

Joe

The 94 and older models have a different gear cut on the input shaft then the 95 and up models. You might run into a problems if the input shaft isn't the same length, since you wont be able to use your 249 for a donor shaft. You can get a new shaft for about $150. More then anything its just a strength issue. If you want to use the 249 input shaft then you want a 96-98 case. If you have to go and buy a case its best to drop the 249 and see what input shaft you have and try to find a case with the same length input shaft .

I am planning on swapping my 249 out for a 242. I just read the other day (forget where) that in 94 or something they changed the bearing size in the 242 so my (98) input shaft will not work in pre 94 models or something like that. anyone know if this is true and if so which years can I use (94 and later or anything after 94)?

Joe

well i found the solution, i can use the front of my case and the rear half of a 93 and earler 242 if i need to. but i found a 242 from a 99 xj, which i shouldn't have a problem with they say

I just noticed that you're doing this on a 5.9, that will be a fun truck in 2wd. I just dropped a 242 in my 5.2 last fall and even with the rear locker it lays a couple of 6 foot patches.

well i found the solution, i can use the front of my case and the rear half of a 93 and earler 242 if i need to. but i found a 242 from a 99 xj, which i shouldn't have a problem with they say

Did you get your 242 out of a ZJ?

I read that if you can get one out of a ZJ (94 and later) it will bolt right on. but if from an XJ or YJ/TJ you will need to swap INPUT SHAFTS or do a half and half type thing.

It came out of a 98 ZJ and the input shaft was the same as my 96 249 so it was a direct bolt on. The only other things that need to be done are:

1) Check the speedo gears.

2)The rear drive shaft rubber boot is an optional install and only needed if you ever was to go back to a 249.

3) The Selec-Trac shifter bazel is optional but makes the linkage easier to adjust and makes the inslall look correct.

4) Swap the wires behind the vic to make the vic work right with the 242.


Did you get your 242 out of a ZJ?

I read that if you can get one out of a ZJ (94 and later) it will bolt right on. but if from an XJ or YJ/TJ you will need to swap INPUT SHAFTS or do a half and half type thing.

As for #2, you mentioned about the Rubber boot on the rear drive shaft, my 249 does not have the rubber boot, I knwo what your talking about tho, I replaced a 231 in a 99 XJ a couple weeks ago and it had the rubber boot, well the yard sent the wrong TC they sent the 242 instead of the 231 and this is where I decided I was going to swap mine, I have wanted to do it for quite some time in my old jeep but could never find a 242 locally and now I foudn one and they are suppose to be sending it to the shop 2day. But this boot was on the 231 and I believe the 242 had the same type of output shaft on it.

Now is the shaft on the 242 the same type as whats on the 249, just the 249 has a longer tail housing?
They told me yesterday when I called for it that their system shows the 242 out of a 99 XJ to be the same as the ZJ. And I told him that I heard the 99 were different and his system showed that only the 242's in the WJ were different. So if this is true if the 99 XJ 242 is the same as the 94-98 ZJ 242's then I should be able to bolt it right up.

Either way it doesn't matter, but it will just save me some time....lol if I don't have to tear them down.

The 249 tail shaft is inside of the case, as where the 242 tail shaft sticks out of the case, not because it is longer its just that the 242 case does not mold around the tail shaft (like the 231). With the 242 the drive shaft end that would slide into the case past the seal in the 249 is now outside, so the outside of the end of the drive shaft will rust with or without the boot. The dealer priced me $60 for the boot and since the tail shaft is protected with by drive shaft and greese that goes over it I said no thanks on the $60 boot.

I just checked hollander and is says that a 97-01 XJ 242 case w/o Police or Export package will fit.

I wasnt too crazy about having to swap input shafts either thats why I avoided having to do it. It just sounded like an extra day of work LOL.

The swap is well worth the time and effort. It's rare to bolt something on to a car/truck and say hey this was totally worth the pain. I'm not sure if your 249 is still good but mine was toast with only 85,000 miles on it and was eating up front tires and made turns like a semi truck. Our I6 ZJ felt more powerful then the 5.2 with the toasted 249. The swap just made this jeep alot more fun to drive.





As for #2, you mentioned about the Rubber boot on the rear drive shaft, my 249 does not have the rubber boot, I knwo what your talking about tho, I replaced a 231 in a 99 XJ a couple weeks ago and it had the rubber boot, well the yard sent the wrong TC they sent the 242 instead of the 231 and this is where I decided I was going to swap mine, I have wanted to do it for quite some time in my old jeep but could never find a 242 locally and now I foudn one and they are suppose to be sending it to the shop 2day. But this boot was on the 231 and I believe the 242 had the same type of output shaft on it.

Now is the shaft on the 242 the same type as whats on the 249, just the 249 has a longer tail housing?
They told me yesterday when I called for it that their system shows the 242 out of a 99 XJ to be the same as the ZJ. And I told him that I heard the 99 were different and his system showed that only the 242's in the WJ were different. So if this is true if the 99 XJ 242 is the same as the 94-98 ZJ 242's then I should be able to bolt it right up.

Either way it doesn't matter, but it will just save me some time....lol if I don't have to tear them down.

Even this guy on Ebay item 230218157750 says the case will fit out of a 99 XJ.

Yea I was thinking of swapping the tail housing, but now I see that it cannot be done that easily because of the speedo gear location. But I know how I will do it, I could prolly get the boot from the dealership for about 1/2 that but it will prolly be a special order. I just ordered the BEZEL and the linkage for the 242 (the linkage I will not need because went they sent the t-case it still had the linkage connected), but I already had them order it so I will use the new one. I guess I will figure something out to seal the yoke/shaft, I guess a good old bicycle (20 inch) inner tube will have to work, I will just cut a section about 8" or so long and slip it over the shaft and yoke and use some hose clamps to hold it in place.

I plan on doing this saturday after work if it's not too cold. I figure it shouldn't take more then 4 or 5 hours to swap in. heck the last one I replaced only took about 2 hours but I was working on a lift.

The 249 linkage that is in your Jeep now will work also, you just need to use the shift plate from the 242. I also looked into ordering the Bezel from the dealer and they wanted $130 for it LOL I ended up calling a few wreckers and got one for $10. The bicycle inner tube is a good idea and should work just fine. Greeze the end of the drive shaft and your good to go. I did mine on the ground and took me 5 hours and about 3/4 of an hour was messing around with a single tranny stud that was oxidized and wouldnt let me slip the t case off the tranny. Also check your rear tranny seal if its leaking this would be a great time to replace it since its a cheap part.

Let me know how things turn out and what you think of the 242 case.

Yea I was thinking of swapping the tail housing, but now I see that it cannot be done that easily because of the speedo gear location. But I know how I will do it, I could prolly get the boot from the dealership for about 1/2 that but it will prolly be a special order. I just ordered the BEZEL and the linkage for the 242 (the linkage I will not need because went they sent the t-case it still had the linkage connected), but I already had them order it so I will use the new one. I guess I will figure something out to seal the yoke/shaft, I guess a good old bicycle (20 inch) inner tube will have to work, I will just cut a section about 8" or so long and slip it over the shaft and yoke and use some hose clamps to hold it in place.

I plan on doing this saturday after work if it's not too cold. I figure it shouldn't take more then 4 or 5 hours to swap in. heck the last one I replaced only took about 2 hours but I was working on a lift.

I heard the 242 linkage was longer then that of the 249, this is why I ordered one, I got the bezel from my dealer for $39 and some change and the linkage and both new grommets for about $45 - they should be here the biginning of the week, I don't need either to put it in, so I will start on it saturday after work.

I'll let you know how it goes.

The 249 linkage that is in your Jeep now will work also, you just need to use the shift plate from the 242. I also looked into ordering the Bezel from the dealer and they wanted $130 for it LOL I ended up calling a few wreckers and got one for $10. The bicycle inner tube is a good idea and should work just fine. Greeze the end of the drive shaft and your good to go. I did mine on the ground and took me 5 hours and about 3/4 of an hour was messing around with a single tranny stud that was oxidized and wouldnt let me slip the t case off the tranny. Also check your rear tranny seal if its leaking this would be a great time to replace it since its a cheap part.

Let me know how things turn out and what you think of the 242 case.

You said I need to use the shift plate form the 242, you are referring to the shiftplate on the transfer case?

Reekor

Do you have any problems shifting your 242. I put mine in today and I had to use my rear shift linkage from my 249 because the 242 was too long it would not connect with the TC in 2WD. well when I got it done now I cannot seem to find each gear they are not very distinct, I do not have the 242 bezel yet, still has my 249 bezel in, I don't know it that has something to do with it, and it doesn't seem to want to go back into 2WD. Did you have to adjust linkage.

Yeah the linkage does need to be adjusted. I had the same issue before I adjusted mine, it would not go into 2wd and was stuck in part-time 4wd. To adjust it without the bezel shouldn't be a problem, you should be able to feel it sort of click into the different ranges. Also when you rewire your vic, you will see only the rear wheels only light up on the vic display in 2wd. Then you should see it say part-time in yellow, full-time in green.


Reekor

Do you have any problems shifting your 242. I put mine in today and I had to use my rear shift linkage from my 249 because the 242 was too long it would not connect with the TC in 2WD. well when I got it done now I cannot seem to find each gear they are not very distinct, I do not have the 242 bezel yet, still has my 249 bezel in, I don't know it that has something to do with it, and it doesn't seem to want to go back into 2WD. Did you have to adjust linkage.

Well I adjusted the linkage, I also bent the linkage where it clips onto the torque shaft because when in 2WD it would hit off of the torque shaft. and swapped out the plugs behind the VIC, so it reads correctly and everything is working perfectly. Now I just have to wait for the bezel to come in and it will be complete.

Good to hear, Let me know what you think of it in 2wd when you get to try it out. The other day we got around a foot of wet snow that just turned into ice and from a dead stop you can tell that the part-time 4wd gets better grip vs full-time 4wd.

Well I adjusted the linkage, I alos bent the linkage where it clips onto the torque shaft because when in 2WD it would hit off of the torque shaft. and swapped out the plugs behind the VIC, so it reads correctly and everything is working perfectly. Now I just have to wait for the bezel to come in and it will be complete.