ZJ 249/242 swap linkage issues

[NUXJR]

Okay fellow ZJ jeepers.  I've got the t-cases swapped and all seems to be okay so far but have linkage trouble.  Done some searching on this forum and some others, but no clear answers.  Some people have suggested that the actual handle needs to be changed out, some say do that AND change primary linkage rod and some suggest don't change anything.

The other thing to figure out is the wiring.  I did not get the attached wiring with the 242.  Will it be better to chase down the proper plugs/wiring and adapt that or fashion something from scrap?

cLay?
Apeman?
Johnny?
Jay?
?

Any help will be obviously appreciated

[morerpmfred]

Swapped from a 249 to 242 ?  Novak makes a neat shifter that can handle all the issues. I went from a 231 to a 242 and yes there is some isues as there is now an extra gate doqn below and not a gate on current linkage. Swapped the short arm of the 231 put in backwards to make it shift properly. A sixtenth of an inch either way then I lose either low range or two high. Presume the 249 has three gates versus the five gates on the 242 oe four  gates on the 231.
Hope this helps figuring it put.

[CatSplat]

Hmm, I did the swap on my '94 V8 and had no problems whatsoever. Did you use the shorter shift tab from the 242?

[NUXJR]

Yeah thanks guys.  The 249 is out 242 is in.  Kept the short arm on the 242, adjusted to both extremes, it's the 2wd and 4lo that have issue cuz they are at the top and bottom ends of linkage travel.  Can get them to barely engage but they don't 'pop' in like normal.

[rws]

Swapped from a 249 to 242 ?  Novak makes a neat shifter that can handle all the issues. I went from a 231 to a 242 and yes there is some isues as there is now an extra gate doqn below and not a gate on current linkage. Swapped the short arm of the 231 put in backwards to make it shift properly. A sixtenth of an inch either way then I lose either low range or two high. Presume the 249 has three gates versus the five gates on the 242 oe four  gates on the 231.
Hope this helps figuring it put.

X2.  Novak makes a couple of shifters than are many time better than factory linkages.    Go to their website and see if something will work for you.

[NUXJR]

Novak cable shifter looks pretty cool.  Who in town would carry their stuff?  Was hoping to find a less expensive alternative but Novak shifter could prove to be best long term option.

[Fredduck]

Check this one out.
http://jeephorizons.com/tech/tcase.html

[tubby]

Novak cable shifter looks pretty cool.  Who in town would carry their stuff? 

Jay at Chanda is the only Canadian dealer for Novak.  Weren't you just there the other day Rob? I've fiddled with the stock linkages for years and decided to buy a Novak shift cable for my T-case swap. It's a night and day improvement in regards to smoothness and positive shift feel. It's pricey(under $300) but worth it in my mind.

[apeman]

I had to fab a link to get full throw on the last swap I did. Use the 242 tab and a 14.5" link. Worked fine

[NUXJR]

I had to fab a link to get full throw on the last swap I did. Use the 242 tab and a 14.5" link. Worked fine

That's the link I think ya showed me when I was over there right?  Any chance you can make another one?

Sounds like the Novak shifter will likely be in the neighborhood of $250+.  That's a good down payment on a bumper

[JackstandJohnny]

pull the shifter bezel off and see if it shifts smoother.  it could also be a quirky transfercase. i don't think my 231 has ever been in 4low until i  bought it.  it didn't shift as freely as the YJ one.  new one shifts a lot nicer when the jeeps running....

mine also would pop out of 4low once and a while. i notched the bezel part and no more issue.

[NUXJR]

Good stuff Johnny .  Been working the shifter a bit and it seems to be getting progressively better but still not 'popping' in 2wd and 4low they way I think it should.

Did some investigating with my parts guy here at work and looks like there are 2 different part numbers for the primary linkage rod, one for 242, one for 249.  Gunna bring in the 242 one and see if it's a little longer than the 249 one.  If it is, then maybe that will help things shift a bit better.

The other thing I'm working on is that the plug on the 242 for the shift indicator wiring is different than what the 249(4pin) had.  If I swap the one from the 249 in to the 242 will it work properly?  Guess I could try, eh?

[JackstandJohnny]

http://www.jeepforum.com/forum/f13/transfer-case-swap-info-np249-np231-np242-685644/


try this link Rob. there should be some info on your connectors.

my connectors fo rthe 231 don't work. the sensors in the tcase were different so i left it out.  i don't really care. i can tell when its in 4wd...........

[NUXJR]

Yeah I've spent a few nights looking over that write up and a couple more.

Just spent more time with my parts guy and guess what....part number for both 249 and 242 ZJ selector are the same.  So I'll put it in and let y'all know if it works

[apeman]

If all else fails i will make up a link for you monday at work. Just bring me your old link, so i have one for future swaps..