ZJ 231 Swap

[jsteves]

I just picked up my 231 yesterday and the owner had to keep the speedo gear housing for his Atlas, will the one from my 249 just plug right in??

However, if i am not mistaken, there is an adjuster on the speedo housing that may need to be adjusted. if it is too tight it will apple core the speedo gears.

[Cue-Ball]

Yes the speedo housing rotates to adjust for the speedo gear size.

[Tyson]

Okay, found the shift cover part number its #5521.7369

Now as for the tab:



Is it #12 in this pic?

I got with my local Jeep dealer and he didn't have a clue. He swears up and down that the 231 did not come in the ZJ and that the part number 5209 8319 is for a whole transfer case priced at $1000.

I'd like to get this swap done this weekend. I have a 231 out of a 92 XJ that had an AX15 and it is the short input shaft. I also have a xfer case out of a 92 Dakota that has the long shaft. I don't know what my 249 is yet but I will first thing Saturday morning. I just want to make sure I have everything I need, including this "tab", so I can do the swap.
Thanks y'all.

[DougMangi]

i just cut the one we from the 249....



works perfect for me, shifts better than the 249 ever did

[Tyson]

What did you cut? Is the hole to hole measurement the same and you rounded the outside? Got a before shot? 'course, I guess I could go look at my wifes ZJ.

Thanks.

[DougMangi]

yeah the wholeoutside is an oval before, no before shot, sorry, something was in the way before, the tab couldn't move past it, so we took that L shaped slot out of the bottom left

[Tyson]

Okay, I just finished pulling the 249 out of a '95 ZJ. It has the long input 23 spline.

I have two other transfer cases in my garage.
#1 231J out of a '91 XJ with short input
#2 231D out of a '92 Dakota with long input

The inputs of the dakota and the ZJ are the same. Is there any reason I can't combine the 231j and 231D? or Can I put the entire 231D strait in?

I want to get this done tomorrow.
Thanks Everyone.

[jsteves]

if the inputs are the same you can throw it in...linkage will need some adjusting though

[Tyson]

It's all good. Thanks to everyone for the info and the advice.
The final outcome was as follows.
95 Grand Cherokee V8 with np249 with long input.
I used the front half of a 92 Dodge Dakota 231D with a long input and the back half of a 91 XJ 231J. I also used the shift linkage off of the cherokee and adjusted the upper linkage a little. I used the speedo out of the 249. the only thing that doesn't work is the sensor that tells you what position your tcase is in. Oh, darn.

Everything bolted up great and it doesn't make any sound going down the road. Again, thanks for the advice all.

[carnuck]

I'm thinking about playing this game in sort of reverse. I have a NV249 that was recently worked on by the Jeep dealer (came from a still driving but not street legal tee boned '93 ZJ with 4.0L AW4) New chain and resealed. I tried the figure 8 test, but couldn't turn the ZJ far enough to the right to tell (one lower arm on the front diff was bent with the bracket) but it seemed to work fine. No-one near me in Seattle wants it for $100 but lots are interested in the NV231 in my '93 XJ (4.0L with AW4 also). Since it's the wife's rig, making it full time 4x4 isn't much of an issue because our driveway is a 6 mile class 1 trail.
My big question is "Do I need to mod the driveshafts or are they the same length?" I have the ZJ front shaft, but the rear was bent and probably a different length anyways.

[Tyson]

The 231 out of a 91 cherokee and the 249 out of a 95 ZJ were the same leangths and had the same outputs. It should work providing you follow all of the info provided in this post.

[greenhunter]

I just swapped out my 249 in favor of a 231 from an 01 TJ. Fit perfectly except for the rear DS being too long (I'll address this by doing what swampboy did).

The only other problem I can see is that I think the 231 is clocked a little differently. If the front drivers side flexes any, it looks like the front DS will come in contact with the crossmember. Has anyone else had this problem? I'm thinking of cutting and rewelding the crossmemeber a little bit, but i'm worried about strength issues. Any advice?

[zj-monster]

someone was asking about a 242 write up so I thought I would provide it. It even comes with a burn out pic at the end. Enjoy.

http://jeephorizons.com/tech/tcase.html

Damn Swampy, your ZJ is super SMOKIN'!!

[Supershafts]

Just curious if anyone knows as to what other cases will bolt to the trans (46/5.2) in the ZJ other than the 231...what about the 241 or hd version or 271? ?

[DJJordache]

someone has done the 241 but you don't hear much about this swap b/c they are harder to find and more expensive to get. Heck, it's easier to find a 242 AMG out of a H1 than a used 241. with $$ anything is possible

[Supershafts]

Anyone know what's involved with the 241, after reading this i wonder how many more shots that case is gonna take before it grenades, and i was gonna add another 75 hp to it....i'll wait and see what's what with the 241 or hd install

[Skyline]

After reading this thread, I still haven't made up my mind about whether to go with a 231 or a 242. Living in the Northeast, a FT 4WD option is really nice, but the 231's extra strength does sound like a good idea. The idea of a 242HD sounds like the perfect solution. What did they come in? Are there other issues that would make one more difficult to swap?

I know there are vendors who can sell you a fully built 242HD with all the right shafts/splines/etc to bolt right up to my current DS's and trans, but they want something like $1,200, (fully waranteed mind you, but still a lot of money!)

[carnuck]

There is always the NP208J from a Full size FSJ. ('80 to '88 as an option with auto and standard equip with manual trans) I haven't test fit the one I have to the 42RE I have (to see if it needs a clocking ring for a spacer) but it's factory fixed yoke and stronger than the NP231.

[DJJordache]

What did they come in? Are there other issues that would make one more difficult to swap?

I know there are vendors who can sell you a fully built 242HD with all the right shafts/splines/etc to bolt right up to my current DS's and trans, but they want something like $1,200, (fully waranteed mind you, but still a lot of money!)

they came in the durango 98-2000 probably others...
they even have 23 spline input and 27 output. they also have .840 input length which is the same as the 96-98 ZJ 4.0L and maybe some v8's, but the input should be able to swap if it's not right for your application.
the bad thing about it is that it has NO speedo hole b/c the durango has the speed sensor at the wheel if I remember correctly.. and the rear driveshaft length might have to change since the durango case has internal slip vs the ZJ 96-98 242 external slip but might be ok if you have a 249 since they are internal slip already

[carnuck]

I test fit the NP208J to the 42RE I have last night. If the centering nub wasn't there (on the trans output shaft) it would bolt right up. A thick clocking ring would allow it to work.

PS: If anyone needs a NV249, it ends today(sold for $50!)

[Skyline]

they came in the durango 98-2000 probably others...
they even have 23 spline input and 27 output. they also have .840 input length which is the same as the 96-98 ZJ 4.0L and maybe some v8's, but the input should be able to swap if it's not right for your application.
the bad thing about it is that it has NO speedo hole b/c the durango has the speed sensor at the wheel if I remember correctly.. and the rear driveshaft length might have to change since the durango case has internal slip vs the ZJ 96-98 242 external slip but might be ok if you have a 249 since they are internal slip already

I guess that's the same as a regular 242 TC. '99 on used the electronic speedometer. Anyone know any pre-'98 applications for the 242HD???

[nate]

241 and 241HD should be fairly common, that's Cummins powered Dodge trucks have, maybe the gassers too?

I swapped from a 249 to a 242 then to a 231, never changed input shafts, shifter linkages, etc and I've never had a problem. 242 was from a ZJ and the 231 from an XJ.

[carnuck]

ZJs went to electronic speedos in '94 AFAIK. I have the VSS from one in my parts collection.

[Skyline]

ZJs went to electronic speedos in '94 AFAIK. I have the VSS from one in my parts collection.

I think the concern is for us ZJ guys not to try to use one of the later TC's that have no speedometer hole at all. You can easily switch a sensor, but if the case has no hole, you have no speedo.

Take a look at this chart:

http://www.drivetrain.com/transferca...AND%20CHEROKEE

[Supershafts]

No offer of a 241? i wonder if then you wouldn't be able to use a 241 or 241hd at all?