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  1. #1
    Chris Jeep98ZJ's Avatar
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    242 swap PICTURES PLEASE

    Just did mine tonight. 242 from a 96 ZJ 4.0 and it wasnt exactly a bolt in. Nothing much but i had to swap the speedo sending unit over because the lugs were different as well as the gear. The 96 had 3.55 gears and our 5.9s have 3.73 gears. Also the case measures about 1 1/2" longer than the 249 which makes the driveshaft a little long for my liking. Anyone who has done this run into the same issues? Anyone who has done this swap can you please post pictures of your swap? Id like to see how yours turned out.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  2. #2
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    I believe the 1.5" difference is due to the D44a rear axle having a 1.5" longer pinion then the D35 rear axle vehicle that the 242 came out of.

  3. #3
    Chris Jeep98ZJ's Avatar
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    Very possible BUT the actual case is longer. Seems they would use the same 242 in the 4.0 and 5.2 and just use different driveshafts not make one case longer than the other. The 5.2 came with the 44a also. Unless of course all 5.2s came with the 249 and never had a 242 option. Then that makes sense.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  4. #4
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    Ahh, ok, gotcha.

  5. #5
    registered user Jeepkid's Avatar
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    ive heard the case being the 1.5 to 2 inch long thing before.. i didnt have this issue.. if it is indeed and issue pull the shafts and put the rig in reverse and use a cut off wheel and it will cut smooth.. they do it all the time on xj shafts
    2010 Dodge Ram 1500 TRX-4 Hemi, 407lb Tq 390+Hp, Navigation, Back up cam.
    '79 Hydrostream Vector w/ 150HP Mercury Black Max outboard.
    '07 Acura Tsx Navi, Back up cam, Projector headlamps
    '98 <TRADED> 5.9 ZJ 14.77 1/4 mile ,3in FM 40 series, HF Cat,E-Cut-out, Mx6 shocks,20x8.5 Cobra R's 255/45/20 Yokohamas, 5% limo tint,Addco 1.25" military bar front, Hellwig 7/8th bar rear, Regeared to 4.10's, 13" C6 Corvette Brake Kit with Dual piston caliper, Wj Control Arms, Doug Thorley headers, 52mm TB, K&N Intake, boxed rear control arms with prothane bushings, Prothane trans mount, Martin Saines custom trans, Aux trans filter, B&M trans cooler, 242 Case swap, SCT Tuner Via hemifever, JL w6v2 sub, JL speakers, Kenwood amp,8 inch indash dvd

  6. #6
    Forum CONDUCTOR Man Z88Z's Avatar
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    OK, I don't think these pics will help too much....

    I've been meaning to post it though cuz I notice it doesn't look like everyone else's 242. Seems like all the others have a bare output shaft rather than this housing.









  7. #7
    Chris Jeep98ZJ's Avatar
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    Yea that looks different than mine. Ill post pictures of mine shortly. If i cut anything it wont be the transfer case shaft, it would be the yoke on the driveshaft. I actually may have to cut both lol. It seems like the driveshaft has about 1" of play before it bottoms out against the case.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  8. #8
    RallyJeep GO
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    All ZJ 249s, and 93-95 ZJ 242s have the internal slip rear DS yoke. The 96-98 ZJ and 96-01 XJ 242s have the bare shaft and boot (external slip yoke).
    1998 ZJ 5.9 Limited - Deep Slate
    Mods: Big trans cooler, 231 swap, Indy MA-X heads prepped by IMM, Comp 20-744-9 cam, 1.7 HS roller rockers, 52mm TB, Airgap manifold, DT headers and full 3" exhaust, SCT tune homebrewed by me, Martin Saine valve body, B&M tranny pan, magic suspension made from unicorn tears, power steering cooler, lots of lighting mods

  9. #9
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    Mine is an external slip...

    01' XJ was the donor vehicle.

    My drive shaft has plenty of play in it and I am lowered on H & R's...
    1998 ZJ 5.9L V8 - Endless mod list... - SOLD
    2004 Lincoln LS 3.9L V8 - Loving it still!


  10. #10
    Member NoTime's Avatar
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    I spun 3/4" off the end of the tailshaft of the 242 for my 5.9 Just used a cut off grinder and took it very slow as to not heat it up too bad. ( did this on bench before putting it in Jeep ) You might be able to get away without doing this but I figured on compression of the drive shaft ( going into the TC ) that I did not want it bottom out on front yoke of the rear drive shaft



    The 5.9 has a larger dia Rear Driveshaft ( hence the larger U-Joints ) I did not want to cut that down
    1998 ZJ 5.9 Platinum - 408 SC Sleeper ( 7.49 / 11.? )
    2012 RAM - Tow Vehicle
    2007 GC SRT8 Daily Driver
    2003 TJ Rubicon Inca Gold - Trail blaster
    1973 Trumph GT6 MK III
    20 Ft Enclosed Car Hauler

  11. #11
    RallyJeep GO
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    Limited360 - Lowering it gives a longer driveshaft length, so that's why yours fit fine.

    NoTime - That looks pretty much the same as what I cut off mine.
    1998 ZJ 5.9 Limited - Deep Slate
    Mods: Big trans cooler, 231 swap, Indy MA-X heads prepped by IMM, Comp 20-744-9 cam, 1.7 HS roller rockers, 52mm TB, Airgap manifold, DT headers and full 3" exhaust, SCT tune homebrewed by me, Martin Saine valve body, B&M tranny pan, magic suspension made from unicorn tears, power steering cooler, lots of lighting mods

  12. #12
    Chris Jeep98ZJ's Avatar
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    I thought this was a bolt in with no cutting or anything? This is the first im hearing of anyone doing this. Mine is the exposed shaft but i dont have a boot over anything.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  13. #13
    RallyJeep GO
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    The boot is optional. It's technically bolt-in, but it's a little tight without cutting, so some of us did that just for the safety margin.
    1998 ZJ 5.9 Limited - Deep Slate
    Mods: Big trans cooler, 231 swap, Indy MA-X heads prepped by IMM, Comp 20-744-9 cam, 1.7 HS roller rockers, 52mm TB, Airgap manifold, DT headers and full 3" exhaust, SCT tune homebrewed by me, Martin Saine valve body, B&M tranny pan, magic suspension made from unicorn tears, power steering cooler, lots of lighting mods

  14. #14
    Chris Jeep98ZJ's Avatar
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    OK here is what mine now looks like. The driveshaft as about 1" before the yoke would bottom out on the case. The Depth of the yoke is more than the length of the output shaft. The yoke would hit the case before the output shaft would bottom out inside the yoke.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  15. #15
    Junior Member mike_5.9's Avatar
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    Quote Originally Posted by Jeep98ZJ View Post
    OK here is what mine now looks like. The driveshaft as about 1" before the yoke would bottom out on the case. The Depth of the yoke is more than the length of the output shaft. The yoke would hit the case before the output shaft would bottom out inside the yoke.
    mine look's exactly like yours. I've been driving it with absolutely no problems what so ever for a couple weeks now. I didn't cut anything, just swapped the 242 in and bolted everything back up and adjusted the linkage. Unless your getting into some funky articulated predicaments, I don't think it's gunna be a problem. My 9er stays on the street and prolly will never see any kind of off-roading therefore I'm not worried about mine. After the install, I had a fat dude bounce on the back of my 9 while I watched the shaft move. It didn't even come close to bottoming out. It hardly even moved to tell you the truth.

    good luck

    Mike

  16. #16
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    242 swap PICTURES PLEASE

    I bought the boot and put it on for the costs... ~$30 for the two clamps and the boot... All said and done... Under $200 and 10" wide patches can be left on the pavement
    1998 ZJ 5.9L V8 - Endless mod list... - SOLD
    2004 Lincoln LS 3.9L V8 - Loving it still!


  17. #17
    Chris Jeep98ZJ's Avatar
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    Quote Originally Posted by mike_5.9 View Post
    mine look's exactly like yours. I've been driving it with absolutely no problems what so ever for a couple weeks now. I didn't cut anything, just swapped the 242 in and bolted everything back up and adjusted the linkage. Unless your getting into some funky articulated predicaments, I don't think it's gunna be a problem. My 9er stays on the street and prolly will never see any kind of off-roading therefore I'm not worried about mine. After the install, I had a fat dude bounce on the back of my 9 while I watched the shaft move. It didn't even come close to bottoming out. It hardly even moved to tell you the truth.

    good luck

    Mike
    Nice thanks thats good to hear. My 5.9 is at stock ride height and will never see any off road use. Just for the hel of it, can you post a picture of yours? What year case do you have? Has anyone else had to swap over the speedo sending unit?

    limited360, id like to get the boot also just to protect the splines. Where did you buy the parts?
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  18. #18
    Member NoTime's Avatar
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    On my install it seemed tight so I did the little cut off,,, in fact I think I sliced a bit off the end of Yoke as well so like you said if it bottomed out on the shaft the Yoke would not take out the end of TC. Most likely not needed but it is done now.

    As to the Rubber cover,,,, check at dealer and ask them for an 98 XJ 242 parts list and it should show it. I only have the ZJ listing and it is the other style with the outer longer housing
    1998 ZJ 5.9 Platinum - 408 SC Sleeper ( 7.49 / 11.? )
    2012 RAM - Tow Vehicle
    2007 GC SRT8 Daily Driver
    2003 TJ Rubicon Inca Gold - Trail blaster
    1973 Trumph GT6 MK III
    20 Ft Enclosed Car Hauler

  19. #19
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    242 swap PICTURES PLEASE

    Dealer... 01' XJ for me... Just cause I knew that was year of case... But 97-01' XJ works.

    I love my 242 in the wet... Too much traction on dry really...
    1998 ZJ 5.9L V8 - Endless mod list... - SOLD
    2004 Lincoln LS 3.9L V8 - Loving it still!


  20. #20
    Junior Member mike_5.9's Avatar
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    Quote Originally Posted by Jeep98ZJ View Post
    Nice thanks thats good to hear. My 5.9 is at stock ride height and will never see any off road use. Just for the hel of it, can you post a picture of yours? What year case do you have? Has anyone else had to swap over the speedo sending unit?

    limited360, id like to get the boot also just to protect the splines. Where did you buy the parts?
    I'll post a picture up tomorrow morning when I go outside. My case was stamped 11/95 and was removed from a 96 ZJ I believe. The speedo gear needed to be swapped on mine as well, wasn't a big deal though. The biggest PITA for me was removing the rusted in studs from the 249 and swapping them to the 242. The guy who removed my 242 threw the bolts w/ studs still attached into the trash

    I'll have them pics up tomorrow

    mike

  21. #21
    Chris Jeep98ZJ's Avatar
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    lol that sux. I had 2 come out that way also but just put them back in no biggie and yes the speedo gear is all of a 10mm bolt no biggie at all.

    OK so i just did the VIC wiring and went through the gears on the t case. Everything seems to work BUT the case doesnt seem to have enough throw to go into 4lo and when i did force it back into 4lo the VIC says part time?
    Last edited by Jeep98ZJ; 11-18-2010 at 06:21 AM.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  22. #22
    registered user Jeepkid's Avatar
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    the vic will say part time on 4lo.. your not suppose to run 4lo all the time only when you need to get unstuck
    2010 Dodge Ram 1500 TRX-4 Hemi, 407lb Tq 390+Hp, Navigation, Back up cam.
    '79 Hydrostream Vector w/ 150HP Mercury Black Max outboard.
    '07 Acura Tsx Navi, Back up cam, Projector headlamps
    '98 <TRADED> 5.9 ZJ 14.77 1/4 mile ,3in FM 40 series, HF Cat,E-Cut-out, Mx6 shocks,20x8.5 Cobra R's 255/45/20 Yokohamas, 5% limo tint,Addco 1.25" military bar front, Hellwig 7/8th bar rear, Regeared to 4.10's, 13" C6 Corvette Brake Kit with Dual piston caliper, Wj Control Arms, Doug Thorley headers, 52mm TB, K&N Intake, boxed rear control arms with prothane bushings, Prothane trans mount, Martin Saines custom trans, Aux trans filter, B&M trans cooler, 242 Case swap, SCT Tuner Via hemifever, JL w6v2 sub, JL speakers, Kenwood amp,8 inch indash dvd

  23. #23
    Chris Jeep98ZJ's Avatar
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    ah yea i know that lol i just thought it would say lo or something like that. If you look at the VIC i believe it has a section that can light up and say lo
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

  24. #24
    RallyJeep GO
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    It can display "LO", but the sensor only reads 3 positions, and it reads the same in 4PT and 4LO. The LO light is only used with the 249.
    1998 ZJ 5.9 Limited - Deep Slate
    Mods: Big trans cooler, 231 swap, Indy MA-X heads prepped by IMM, Comp 20-744-9 cam, 1.7 HS roller rockers, 52mm TB, Airgap manifold, DT headers and full 3" exhaust, SCT tune homebrewed by me, Martin Saine valve body, B&M tranny pan, magic suspension made from unicorn tears, power steering cooler, lots of lighting mods

  25. #25
    Chris Jeep98ZJ's Avatar
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    Gotcha. Part time is for offroad use full time is for street use am i right? The 242 thing is new to me lol.
    Platinum 5.9 167K when i bought her. 2.25" engine pipes 3" Magnaflow cat, 3" Hooker Aerochamber, 3" tail pipe, Ported kegger, 52MM Throttle Body, 24lb ford injectors, K&N drop in filter, Cast JEEP valve covers, MSD coil and wires, All new 6 piece clear light kit, 255/65/16 General Grabber HTS, 242 conversion, XJ u-joint front axle shafts

    96 Dodge Ram 1500, 5.2, picked up 12/3/13, 191K miles, edelbrock air cleaner, dual catback exhaust, headers, 50MM TB, 26,000 GVW tranny cooler, 4" lift, 35" General Grabber AT2 tires on Mickey Thompson Classic wheels.

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