OldJudge

so my mystery sound was not the CV joints, not the differential despite the seal leak (minor), and not the double cardan or front U joint -

........its the F'in Transfer case - Duh, little did i know what miserable sounds a cooked Viscous Clutch sounded like - it sounds like all three of the above problems combined but put under a pillow, muffled... like its inside something... like a transfer case, lol - ***** ... the most expensive repair!

Having the cooked VC - i removed my front driveshaft - full power to rear now ... but the jeep WILL NOT PARK WHEN DRIVESHAFT IS OFF - IF YOU TAKE IT OFF AND PARK ON A SLIGHT HILL IT WILL ROLL!!! Block your wheel, turn the wheel, and pull the E-brake if you must park on a hill.... or wake up in the morn and wonder where the jeep is.


THIS IS WHAT I FOUND.... WILL IT WORK?

.........a 1990 cherokee limited with a 242j and 118,000miles on it - not bad eh?

sooo ...what i've deduced is this -

my 1993 grand cherokee limited has a 249 Transfer Case (TC) and its finally failed after 233,000!!!!! not bad for a viscous clutch - but i miss the Select-Trac i had on my old red 1990 cherokee limited - went to a salvage yard for guys like us to rip apart after the engine caught fire (injector o-ring failure)

What i would like to know now is this -

would a newer (1993-98) 242 transfer case simply "drop right in" against the 42re transmission on my 1993 grand ltd?

I FOUND A NICE 242j - like i said - but its a 1990 - and I think they have a lesser spline count at 21 splines. I believe by 1993 has 23 splines. These splines are located on the male end of the transmission's output shaft! Given the male end, why would the input shaft length matter? Didn't the 242 come on the 42re in 1993 grand's? This might just be hard to find.... if so. I'm now assuming the the input shafts on the 242 TC's were different lengths due to the many different Transmission's jeep used 93-98? right?

so i guess the bottom line is this - will the 242j selec-trac from a 1990 cherokee ltd {WHAT DOES "J" STAND FOR ANYWAY} fit on my 1993 grand cherokee?

i think the answer's YES - but likely - due to having different spline counts and different transmissions - i think i will have to swap the input shafts for both their length and spline count.

am i on the right track?

OldJudge

Is there an exact swap? like - pull the 49 out and put the 42 in - done! Can i find my jeep with the 42 and use that TC.

...i should just shut up and swap the input shafts and be done.

ol"blue

Check this out. Write-up w/pics. > ZJ Grand Cherokee 249 t-case swap to 242 How-to from KOR!

OldJudge

nice link - I've read it 4 or 5 times now - its pretty clear what needs to happen.

i'm interested in my options with other models - i've been looking around at 242's ... i noticed they're all a little different down at the yard - some have different input shaft housings - not sure what i think about that with regard to sensors.

i guess i'm asking for advice as too which Transfer cases to look for - since i own a 1993 I6 grand cherokee ltd with a 42re trans and a 249 t.case.

what's the best TC to look for - pretending i know nothing - what would you tell me to look for.

ol"blue

I'm not sure on that. You need to send Russ (user name Willys55) a PM and ask his advice. He's the go-to guy when I need correct answers. Here's his Profile page. https://www.cherokeeforum.com/members/willys55-8410/

dukie564

"J" stands for "Jeep"

New Process tcases come in other makes also, inputs and output vary by application

JeepCoMJ

no, it won't work. the '90 is a 21 spline input, the zj is a 23 spline, and they're probably different length input shafts.

OldJudge

little do i know about this "gear cut"

I'm assuming "gear cut" is unrelated to input shaft or is it?

lets say - I swap the input shafts, is there a different internal "gear cut" that will inhibit the 249 input shaft from properly meshing with the internal gears of the 242?

keeping in mind that I'm dealing with specific years: OEM - 1993, 249 (toasty VC) and the transfer case i'm considering having pulled at my local yard is off a 1990 cherokee ltd. -

(its a shame - the 90 cherokee is super nice - 118,000 ...its barely broken in, I bet i could get the rig up and running - {dreams}

anywho... soo the 1990 242j ( "J" for jeep ;-) ) transfer case is a 21 spline operation and won't mesh with the trans - does anyone know if i will encounter a "gear cut" problem if i swap input shafts. I've read about 4 different 249->242 swaps online - props to the boys who posted their work - its seems like some fun work and I understand the input shaft swap pretty clearly but in my...

....online searching, i found a guy with a 93 249 like me .........who put a 94, 242 in .....and apparently had a "gear cut" problem?

does anyone know a little more about this?


p.s. at this point i'm TC fascinated and half crazy - if i don't figure this out this week ... i think my girlfriend will leave me, as i spend most of my time working on it, talking about it, taking care of it, buy things for it...

"who needs a girlfriend when you've got a jeep" - she said - ha?!!!

OldJudge

the 249's not worth the 350$ to replace the VC right? smarter to find this 242 like im doing?

...do the 242's have any notorious wear-outs?

a 242 with 118,000miles on it should still be pretty solid if it comes off a jeep with running boards - meaning maybe the driver took his time and didn't beat on it, abusively.

JeepCoMJ

the gear cut refers to the angle the gear on the input shaft that meshes with the internal planetary gear assembly inside the transfercase. they're not the same, so swapping the inputs is not a viable option.

OldJudge

off to pick my buddies brain about this swap's options. He's a great mechanic - been with jeep's for over 25 years and has seen a lot of their problems over the years

i need to get some expert advice ... although the collective consciousness of our Cherokee forum is quite massive, its hard to find answers at times... its like being a jeep psychic - and many of us are very good -

i certainly know little, and must resource all options to find answers


i like taking care of what i've got - not doing that ....is a waste - make'it last ( i tell myself ...as i cringe past the dealership looking at other jeeps)

OldJudge

the 242 from the cherokee 1990 - will not swap.

i just talked with a Jeep guru shop foreman 50 yr old-wiz-kid... about this swap...

the tcase will not line up with the transmission mounts, it will sag lower. I know other tcases could fit but to avoid... misalignment, gear cuts, and inputs...

I located a 242 from a 1993 with a 42re (like mine) ...its more than 75 bucks... but for 200$ (considering that the shop wants 500$ w/ shipping for a new VC no chain) i can't complain too much - it will fit and I won't have any real problems - hopefully they are same - the only thing i'll have to do is swap the rear driveshafts....?

i guess i won't know until i try to put it back in

JeepCoMJ

you will need to get a shifter handle and bezel from a junkyard grand cherokee with an np242, as well, and adjust the shift linkage.


but, you're upgrading to having 2wd options so it's a great deal.

OldJudge

thus far it sounds like a fit, the 2wd option's great ... also the low lock 4wd - which my older 249 doesn't have.

as for the handle -

the handle is okay to keep, but the housing the handle emerges from must be changed to compensate for the now 5 positions - whereas the 249's housing made linear movements from hi to low

correct me if i'm wrong - i can leave the handle in, but must replace the housing/guide that mounts to the floor - allowing the zig zag movement.

and the nice black marker plate/indicator will cost peanuts at the yard

OverlandZJ

You have another option..

Use the 249's front case half and original input/sun gear with the original 242 back half and internals. This will eliminate the input gear spline count and gear cut change issues..

BTW- that gear cut change occured in 95.