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View Full Version : 249-231 tcase swap complete



skrracing
02-19-2005, 03:15 AM
I know this has been covered before but I just completed it and wanted to post pictures in case it might help someone out.
I picked up a used 231 out of a 2003 TJ with 18000 miles. The ZJ I have is a 1994 4.0 and using the 249. I also am running the Ford 8.8 rear diff with disk brakes. I have a 6” lift so I wanted to use an Advanced Adapters SYE kit for a couple of reasons. Not just for the drive line angles but I also did not want a slip yoke that sucks dirt in the seal all the time and causes it to leak. The SYE kit solves that problem because it has a flange and is also over 4” shorter with the kit installed. When I picked up this ZJ it had a mix of Tera, RE, and JKS control arms. I really wanted to move to all RE stuff along with the Mono Tube shocks. I have used this setup on other jeeps and it works great. The Tera and the JKS bushings were shot so it was a great time for an upgrade anyway. I went down to All J Products in Colton CA and they had everything I needed to get this job done. They also use the J.E. Reel driveshaft. And Quinn was able to find the 231 tcase for me. We pulled the 249 tcase out and by chance it had the same length input shaft on both the 231 and the 249. Those shafts have to be the same. The 249 input shaft will fit in the 231 case but you have to be sure of the right gear cut and also the spline count on the input shaft. There seems to be an older 21 count spline and the newer 23. The 249 and 231 I had both had the 23 spline count. Also the shift lever is different from both of these cases. You have to use the right one…Be sure to use the lever that came with the tcase. The short one if the 231 and the longer one is the 249. You can not use the longer lever from the 249 on the 231… it will fit but will not allow the 231 to shift right. Pulled the 249 out…installed the SYE kit in the 231…installed the 231 in the ZJ. Measured for the new drive shaft and called it in . Had it the same day and installed it. Filled the case, ordered the new shift pattern plate from the dealer and everything worked great. Set the new pinion angle in the rear and took it for a test drive…no vibes at all. I know this has been covered a few times but just wanted to give an update on the swap. Was a very easy swap to do and had no problem at all. Later...Clint

http://www.lostkjwest.com/images/231a.jpg

http://www.lostkjwest.com/images/249a.jpg

http://www.lostkjwest.com/images/231b.jpg

http://www.lostkjwest.com/images/249b.jpg

http://www.lostkjwest.com/images/231c.jpg

http://www.lostkjwest.com/images/249c.jpg

http://www.lostkjwest.com/images/231d.jpg

http://www.lostkjwest.com/images/249d.jpg

Krash80
02-19-2005, 04:52 AM
good post...but damn you've got good luck. I remember my first t-case swap all i wanted to do was put a 249 from a '96 V8 ZJ into my '93 V8 ZJ to replace my old 249 and get lo-lock, and not a damn thing matched and i spent two days piecing shit together and swapping input shafts and stuff and it still never worked right...tried 2 other t-cases w/ no luck, then finally said the hell with it and ordered a 900$ 242 from Transfer Cases Unlimited cause i couldn't stand screwing w/ it anymore. glad to see that worked out for you so easily though.
-Ron-

OverkillZJ
02-19-2005, 01:56 PM
I'm glad it worked out for you, I had a similar experience as Ron. Ended up throwing down $750 for a 231HD w/ SYE from JB Conversions, but maybe I'm just impatient :)

Jim311
02-19-2005, 02:36 PM
You guys are making me want to reconsider buying this 231 for a swap. It's out of an 88, but I'm getting it for 100 bucks. I planned on rebuilding it anyway, and I figured I'd get a new input shaft as well. Should I reconsider and just go with one I know will bolt up, even if I end up paying a few hundred more?

robselina
02-20-2005, 12:52 AM
You guys are making me want to reconsider buying this 231 for a swap. It's out of an 88, but I'm getting it for 100 bucks. I planned on rebuilding it anyway, and I figured I'd get a new input shaft as well. Should I reconsider and just go with one I know will bolt up, even if I end up paying a few hundred more?

Get one in the right year range so you can swap inputs. I used a 96 XJ I found on NAXJA. It was in great shape with 60k on it and it was only like $175 (like $220 shipped) and that was w/o looking around much 'cause I was impatient and wanted to get it done.

After you buy an input shaft you'll be in that price range anyway so might as well just make life easy and get the right year....

DougMangi
08-08-2005, 12:44 AM
ok maybe this is a dumb question but, is there a drive shaft measurement anyone can use? i mean is there THAT much difference between one ZJ and another? i have the 231 and an SYE for it, and i dont want to have to put the thing in and measure and have it sitting there waiting for the shaft. so, with 4.5" of lift and a D35 rear, what length am i looking at?

rccolacc
08-09-2005, 02:09 PM
Jim311,
I'm in the process still of installing my '88 231 into my '97 Grand. I've tried to install it twice and have run into problems each time. I posted it here:
http://mallcrawlin.com/phpBB/viewtopic.php?t=2584
If you learn from my mistakes, I'm sure you could do it in one shot. Hopefully this third time when I install it, it will work. The price is right though. A 231 for $100 is a good deal, even if you have to replace some bearings.

How much is that new shift pattern plate from the dealer? I need to buy one for the 231.
-RC

nate
08-09-2005, 03:03 PM
I went from a 98 249, to a 98 242 to a 99 231 and they were all bolt in.

skrracing
08-10-2005, 02:47 AM
hey Doug, Not sure what driveshaft shp you are using but you will need to know how they measure the driveshaft and then order it once you have installed the Tcase and then take a measurement. I know it is kind of a pain to do this but to get it right the first time...install the t-case and then take a measurement the way the shp tells you to and it will be a done deal.

skrracing
08-10-2005, 02:50 AM
I have found that if you take a 231 froma straight 6 and install it in a straight 6... a 231 from a v8 and install it in a v8... there are a lot less problems. seems like the setups are always a lot closer for the imput shaft length. But you should be able to do some shaft swapping to get the right lenght. Hope that helps. later...Clint

steves88vb
12-02-2005, 12:25 AM
any pics btw of the 231 linkages installed

skrracing
12-02-2005, 01:17 AM
If you are talking about the little linkage on the t-case...be sure to use the same linage that came with the 231. You have to use the same link that came with the t-case and it solves a lot of problems. Matter of fact I used the same link that came with the t-case I picked up and did not even have to make an adjustment on it. The main thing I changed was the shift pattern bezel...Not that that changed anything but just changed it for looks. Hope that helps. later...Clint