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Old 02-15-2008, 05:48 AM   #1 (permalink)
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Grand 249 to 231 swap

I have done some research but dont feel confortable doing this swap yet.

I have a 98 ZJ ltd. 5.9L with the NP249 thats VC is gone. I picked up a NP231 from a 98 TJ.

Can anyone tell me if it'll swap in the way it is or if i have to change the input shaft with the NP249?
Anything else i should look to change?

If someone has a link for a right up of this swap with good pictures that would be great as well.

Thanks, John
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Old 02-15-2008, 06:18 AM   #2 (permalink)
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lots of info on this on google. i did one on my cousins grand.

basically, look at your 249 input, if its longer than the tj one, you will have to swap them.

the input gears should be the same gear cut so they will interchange between the 249 and 231.

remove the yokes front and rear off both cases, drain the fluid, split the case, pop some c clips and remove the front input seal, hit the input with a hammer gently, and it should come right out. its really simple. once you pull the case apart you will see what i am talking about. swap the zj input with the tj one and button up the 231 and install it in the zj.

keep in mind you will have to re work the linkages for the t case and probably need a new rear drive shaft.
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Old 02-16-2008, 07:11 PM   #3 (permalink)
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I did the swap last March, it's fairly simple once you get into it. I had to swap my input shafts, got my 231 for a 96 XJ. But yeah getting the linkage right took some time.

Here's some measurements that'll help you find out if you're gonna have to swap inputs or not, chances are you probably will need to though.

Originally Posted by DJJordache
this should help ya... the only one I don't know about are the ones that came with the AX15.....
ZJ 93-93.3 4.0L aw4 = short
ZJ 93-95 4.0L = medium with internal collar
ZJ 96-98 4.0L = medium without internal collar
ZJ 93-95 v8 = long
ZJ 96-98 v8 (both) = medium without internal collar
short = .750" exposed
medium = .840" exposed
long = 1.55" exposed
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Old 02-16-2008, 10:55 PM   #4 (permalink)
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Might wanna do your rear wheel bearings while you're at it, unless you wanna buy new axle shafts.
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Old 02-18-2008, 01:15 PM   #5 (permalink)
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Thanks guys, Seals and bearings were just replaced in my rear so thats fine.
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Old 02-18-2008, 02:47 PM   #6 (permalink)
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Might wanna do your rear wheel bearings while you're at it, unless you wanna buy new axle shafts.
Pardon my ignorance but WTF do rear wheel bearings have to do with a 249 swap?
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Old 02-19-2008, 03:42 PM   #7 (permalink)
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I am guessing he means might as well do it since you got the jeep ripped apart not sure.

Found out its a 242 not a 231. Im guessing theres not a big deal being a 242 instead but correct me if im wrong.

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Old 02-19-2008, 04:21 PM   #8 (permalink)
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I am guessing he means might as well do it since you got the jeep ripped apart not sure.

Found out its a 242 not a 231. Im guessing theres not a big deal being a 242 instead but correct me if im wrong.
this info can all be found in a quick search...


input shafts will swap between the following

231
242
249

the 242 will have the full time and part time option. now tear out the pos 249 and swap the inputs!
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Old 02-20-2008, 08:59 AM   #9 (permalink)
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Yeah but the 242 isn't as strong and who cares about full time 4wd anyway.
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Old 02-20-2008, 09:50 AM   #10 (permalink)
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Yeah but the 242 isn't as strong and who cares about full time 4wd anyway.
242 is actually supposed to be stronger than the 231, but there is no after market for them, they are heavy and bigger than a 231, which is why they are normally swapped out. i loved my 242 when my jeep was a DD and even in the sand or on trails.
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Old 02-20-2008, 10:08 AM   #11 (permalink)
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Quote:
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Pardon my ignorance but WTF do rear wheel bearings have to do with a 249 swap?
Because the rear wheel bearings in a 5.9 ZJ (the D44a axle) are the same size and style as Dana 35 ones, and the rollers ride directly on the axle shaft. If you don't catch them soon enough when the rollers wear it eats into the axle and you need to buy new shafts, because there isn't a repair bearing available for that application.

I suggested it mostly as a good maintenance thing to do while it's down for a little while (it can be done within a few hours), but also because running that jeep in 2wd puts a lot more strain on that rear axle, so anything that's currently worn or out of spec will very quickly become worse.
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Old 02-20-2008, 11:12 AM   #12 (permalink)
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Quote:
Originally Posted by rehab View Post
242 is actually supposed to be stronger than the 231, but there is no after market for them, they are heavy and bigger than a 231, which is why they are normally swapped out. i loved my 242 when my jeep was a DD and even in the sand or on trails.


This is incorrect, the 242 is rated for less torque. If I were at home I would send you a link to the chart that says so. The chain is narrower on the 242 if I recall. Until I get home, you'll just have to believe me
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Old 02-20-2008, 11:12 AM   #13 (permalink)
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Originally Posted by vetteboy79 View Post
Because the rear wheel bearings in a 5.9 ZJ (the D44a axle) are the same size and style as Dana 35 ones, and the rollers ride directly on the axle shaft. If you don't catch them soon enough when the rollers wear it eats into the axle and you need to buy new shafts, because there isn't a repair bearing available for that application.

I suggested it mostly as a good maintenance thing to do while it's down for a little while (it can be done within a few hours), but also because running that jeep in 2wd puts a lot more strain on that rear axle, so anything that's currently worn or out of spec will very quickly become worse.

Mine wore out and fawked up my shafts, I was just wondering if there was some particular reason you should change one with the other
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Old 02-20-2008, 06:34 PM   #14 (permalink)
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Quote:
Originally Posted by rehab View Post
this info can all be found in a quick search...


input shafts will swap between the following

231
242
249

the 242 will have the full time and part time option. now tear out the pos 249 and swap the inputs!
You can 247 to that list. I've had the same input in a 249, 247, and two 242s.
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Also, instead of mounting the nitrous bottle between the seats, I'd install a cheese toaster.
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Old 02-24-2008, 08:44 PM   #15 (permalink)
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will the input shafts are the same length on both the 242 and 249.

Is there anything im suppose to swap over like the speedo gear?

Looks to me the 242 i got will swap right in the way it is.
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Old 02-25-2008, 01:44 PM   #16 (permalink)
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Originally Posted by vetteboy79 View Post
Because the rear wheel bearings in a 5.9 ZJ (the D44a axle) are the same size and style as Dana 35 ones, and the rollers ride directly on the axle shaft. If you don't catch them soon enough when the rollers wear it eats into the axle and you need to buy new shafts, because there isn't a repair bearing available for that application.
Maybe I'll just let mine go all to hell, so that way I'm forced to put an axle thats worth a damn in it.

johnnybegood_5 just send me that 242 since you wanted a 231! I got a another Grand Limited with the 318 to buy that needs a t case for $500 thats pretty sweet condition!
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Old 02-25-2008, 06:27 PM   #17 (permalink)
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hahaha ok $500 and its yours
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Old 02-26-2008, 05:29 AM   #18 (permalink)
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hahaha ok $500 and its yours
NO no no, the Jeep is $500 but you need to GIVE me the T Case!
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Old 02-26-2008, 02:26 PM   #19 (permalink)
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Quote:
Originally Posted by johnnybegood_5 View Post
will the input shafts are the same length on both the 242 and 249.

Is there anything im suppose to swap over like the speedo gear?

Looks to me the 242 i got will swap right in the way it is.
Next thing to look at is spline depth. the last one I put in (current one) there was a "step" in the input and I couldn't slide it on all the way. The output was about 3/8 too long. the guy that was helping me thought to cut the output, but I wanted to swap inputs. Good thing too, someone had once filled it with gear oil.


I keep hearing about a gear cut change, but I haven't seen it yet.
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Old 03-24-2008, 11:44 AM   #20 (permalink)
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Does anybody know how long the input on the 249? I have a NP208J and a dana 300. I was thinking about swapping in the 208 in place or flipping the 300 and installing it. I just haven't torn into it yet since I'm still waiting on rear upper CA for my ZJ. The np208j has fixed yokes and I was thinking this would be a great swap instead of a NP231.
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Old 03-24-2008, 01:33 PM   #21 (permalink)
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Does anybody know how long the input on the 249? I have a NP208J and a dana 300. I was thinking about swapping in the 208 in place or flipping the 300 and installing it. I just haven't torn into it yet since I'm still waiting on rear upper CA for my ZJ. The np208j has fixed yokes and I was thinking this would be a great swap instead of a NP231.
If you could read, the length for the 249 input shaft was posted above. I don't really know anything about the np208j, but if it were me I think I would flip the d300 and put that in since it has so much aftermarket support and from what I've heard is a damn good t-case.

Quote:
Originally Posted by jfowlzj95 View Post
Originally Posted by DJJordache
this should help ya... the only one I don't know about are the ones that came with the AX15.....
ZJ 93-93.3 4.0L aw4 = short
ZJ 93-95 4.0L = medium with internal collar
ZJ 96-98 4.0L = medium without internal collar
ZJ 93-95 v8 = long
ZJ 96-98 v8 (both) = medium without internal collar
short = .750" exposed
medium = .840" exposed
long = 1.55" exposed
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Old 03-24-2008, 07:23 PM   #22 (permalink)
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Missed the table. I got crosseyed looking at that and searching 3 other forums. So if input shaft is long (ZJ 93-95 v8 = long), and the input shaft on the NP208J is short (.75 inches, exposed) the 208J is short and they won't mesh and I am back to square 1. Same goes for the dana 300 I have (.75=short). Now I assume I have to tear apart both cases and see if these inputs are compatible. 2 different cases, probably not
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Old 03-24-2008, 10:33 PM   #23 (permalink)
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I have a 98 42re with a 94 input shaft (249) in a 2000 TJ NP231. the gear cuts are the same for at least those models. i had a 1989 XJ np231... the gears were definitely cut differently between the 94-up stuff that i had.

here is the reference between the long and medium input shafts... removed:


this is the sleeve in the input shaft. it is cut and on its way out at this point... the bearing was tapped out and the sleeve removed:


here, with their respective planetary sets. it may be easier just to remove and drop in the complete set so long as the gear mesh properly.


the last pic serves one purpose that you need to be alert for. the long spline has a step on it. the transfercases used a narrow bearing or a wide bearing. if there is in fact a difference, the easy way to resolve it is the swap the input bearings. i did this without issue. if you try to put a stepped input into a housing with a wide bearing... it wont go together. if you put a non-stepped input into a narrow bearing housing.... it will allow the planetary set to move front to rear inside the housing... which results in grinding one way (half neutral) and 4wd the other. at least in my case. i had little information when i converted my ZJ to 4wd back in 2001.
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Old 03-25-2008, 05:40 AM   #24 (permalink)
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Thanks man. I guess I have to tear apart both cases and see if there is any interchangibility with the 208 and the 249. I have to find a shematic for the NP249. I think I still have one for the NP208. Now I've got something else to do this weekend
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Old 03-25-2008, 06:57 AM   #25 (permalink)
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gears on the bottom of the input shaft look like they are straight cut on the 208. maybe the planetary gear set will swap like you suggested
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