local dealer search

Service Menu

  Financing Available
  Worldwide Shipping
  Identify your Jeep
  Sign Our Guest Book
  Sending Money Manually

Introductory Menu

  Who the heck is Kevin?
  Bargain Parts
  Photo Gallerys
  KevinsOffroad Stickers
  KOR Parts eBay Auctions
Video Footage of us Playing

New at KOR

  WJ Hard-KOR Light Bars
  XJ Hard-KOR Light Bars
  ZJ Hard-KOR Light Bars
  WJ Desktop Wallpaper
  JK Desktop Wallpaper
  Throttle Body Spacers
  ZJ Snorkel Assembly

Items Around $100

  WJ Roof-Mount Tire Carriers
  WJ Hard-KOR Light Bars
  ZJ Roof-Mount Tire Carriers
  ZJ Hard-KOR Light Bars
  XJ Roof-Mount Tire Carriers
  XJ Hard-KOR Light Bars
  Anti-Death Wobble Steering Packages and Kits
  WJ UpCountry Skidz (NEW)

Track Bar Menu

  ZJ/XJ Track Bar Conversions
  Z/X/TJ Adjustable Track Bars

Steering Upgrades

  ZJ/TJ/XJ Hard-KOR Steering
  WJ ZJ XJ TJ JK Anti-Death Wobble Packages and Kits
  WJ Str. Stab. Relocators
  WJ Hard-KOR Draglinks
  WJ Hard-KOR Tierods
  ZJ Steering Braces
  Steering Stabilizers

Performance Menu

  ZJ Steering Braces

  KevinsOffroad Stickers

Recovery Items

  ZJ Hard-KOR Bumpers
  WJ Hard-KOR Bumpers
  XJ Hard-KOR Bumpers
  WJ Tow Points
  ZJ Tow Points

Protection Parts

  Rock Sliders
  Kevin's Roof Racks
  ZJ Radiator Supports
  WJ UpCountry Skids (NEW)
  Rocker Panel Protection
  ZJ Hard-KOR Bumpers

Shock Absorber Parts

  WJ Shock Mount Kits (NEW)
  Shock Loop Conversions
  Bar Pin Eliminators
  Shock Absorbers

Lift Kits and Parts

  ZJ Leveling Kits
  WJ Leveling Kits
  ZJ Ultimate Lift Kits
  WJ Ultimate Lift Kits
  TJ Coil Spring Spacers
  XJ Coil Spring Spacers
  Adjustable Coil Spacers
  Adjustable Control Arms
  WJ Long Arm Systems
  ZJ Long Arm Systems
  Quick Disconnects

 Features Menu

  Install Instructions
  Video Gallerys
  Photo Gallerys
  Tech Articles
  Jeep Links

 All The Fine Print

  Warranty Information
  Return Policy



Specializing exclusively in *HIGH-END QUALITY* Jeep Parts & Accessories since 1999

602-841-3355 | 3464 West Earll Drive | Phoenix, AZ 85017      

PIcasa Album | Trail Runs | KOR Blog | LinkedIn | MySpace | Facebook | Twitter  


Join Our EXCLUSIVE E-Mailing List Specials Updates

RatePoint Site Seal

249 to 242 Swap, by Wes (Solitude)


NP249 : NP242 Conversion
Written By: Brian Wesley Free

#1 Screw Extractor (Itís a type of ďEasy OutĒ)
10Ē Monkey Wrench
8mm Socket & Crescent Wrench
10mm Socket
13mm Socket
14mm Socket
15mm Socket
18mm Socket & Crescent Wrench
5/32 Punch
9/16 Crescent Wrench (Buy a cheap one, this will be hacked)
9/16 Deep-Well Socket
Flat Head Screw Driver
Phillips Head Screw Driver
Rubber Mallet
Gasket Remover or Razor Blade
Bottle Jack
Jack Stand
Safety Glasses (Stuff WILL fall in your face & eyes)
Snap Ring Pliers (GOOD ones, Spend some money)
Vise Grips

My 1993 Jeep Grand Cherokee V8 5.2

Do your homework. I tried to make this write-up as conclusive as possible, but there is probably something I left out. This is not a factory service manual; do not treat it as such. This is just from my personal experience. I am not an employee of any off-road shop, parts distributor or parts manufacturer. I am a simple off-road enthusiast. This was done in my driveway, by my friends and me, your shade tree mechanics.

I swapped a NP242 from a 1991 Jeep Cherokee (XJ) into my Jeep Grand Cherokee (ZJ) with a NP249. The goal of this swap is to have the following capabilities: 2WD, 4 Part-Time, 4 Full-Time, neutral, 4-Low. I also wanted to do this swap because the 93-95 NP249 does NOT lock 50/50 in 4-Low. If you have a NVP249 from a 96-98 ZJ it DOES lock 50/50 in 4-Low. To make everything mate and mesh you have to remove the input gear from your NP249 and put into your NP242.


Chock your wheels, chock your wheels, chock your wheels. This means, put something in front and behind your wheels to keep your Jeep from rolling and moving any direction. Disconnect the Negative cable from the battery. Get in put it into neutral and pull the handbrake.

Removing the front and rear driveshafts.

The rear is connected to the differential with four(4) 8mm bolts. Unbolt these, and then slide the driveshaft out of the tailshaft of the transfer case.

The front driveshaft is connected in two places. Start by unbolting the four(4) 8mm bolts on the transfer case, then remove the four(4) 8mm bolts on the differential. Compress the front driveshaft, and slide it out.

Removing the crossmember and supporting the transmission.

Start by supporting the transmission. Using a bottle jack or floor jack place the top of the jack right behind the transmission pan.

Remove the four(4) bolts supporting the crossmember.

Remove the bolt running through the bushing that supports the transmission on the crossmember. After removing the crossmember support the transmission using the jackstand under the bushing housing.

Drain the transfer case. This is where your monkey wrench comes in handy. Notice the plugs.

Removing the transfer case.

Disconnect all the connections to the transfer case. The shifter linkage (The rod with the plastic bushing. It pushes through) and the electrical connectors, speedometer and VIC.

There are six(6) bolts holding the transfer case in place. You canít miss them. The first five(5) are easy to remove. The sixth one is on the top passenger side, it is a complete PITA. This is where your donor 9/16 crescent wrench comes in handy (And some of my redneck engineering). There is not enough clearance for you to put a full size 9/16 or even to use a socket. I had to cut the open end off of the wrench and notch the end to attach a piece of rope (The wrench ended up being a little longer than 4Ē. Napa - $3.50 for wrench, $5.00 for some guy to cut it up). Loop the rope over the case and pull from the driverís side. It took both my friend and I to break this nut. (My knots: bowline on the crescent wrench end and two half hitches on the pipe wrench end. I didnít feel like busting it on account of my knots.)

This will take some effort. You need some muscle for this, or a really nice jack. I had the muscle and no jack. This takes two people. Both you and a friend need to wiggle the transfer case till you clear the bolts. If you have a creeper it will make things easier for you and him. Remove the case and place it on the creeper to pull it out from under the Jeep. I didnít have a creeper so my friend and I used a thick towel and placed the case on it to slide it out from under. Have a bucket ready. When you remove the case, a little transmission fluid will leak out of the transmission, so be prepared.
THIS CASE WEIGHS ALMOST 100 POUNDS, BE CAREFUL! I bench 225, this case is very big and awkward to maneuver so make sure you have everything in place and a plan between you and a friend, before you try to take it out.

The cases side by side. NP249 Left. NP242 Right. Note: I have yet to clean up the NP242.

Take a look at the inputsí:


Before I cleaned up the NP242:



Breaking the case.

Start by removing the Speedometer gear so you donít damage it.

Remove the input seal and housing. It is RTVíed. Then remove the snap ring on the input shaft. (Sorry bad picture. It is not the big obvious snap ring. Itís the smaller one closer to the input gear.)

Next remove the three(3) bolts holding the back half of the tailshaft in place. This is also RTVíed.

Next remove the snap ring completely from the mainshaft.

Remove the four(4) bolts holding the front half of the tailshaft in place. Itís RTVíed. Finally you get to pull the tailshaft off.

The next few pictures are pretty self explanatory.

Now you get to remove the back case half. Remove all the bolts holding it together. It is RTVíed. Get out your flat head screw driver or crowbar. There are two outlets built into this case to help you break the RTV seal. One on both sides of the case.

Now remove the back case half.

(Take note to where everything is located so you can put it all back together correctly.)

Remove the chain just like you would on your bike. Itís pretty simple.

Remove the mainshaft. This is what it should look like to this point.

Now to remove the shifter assembly (Inside the case). By the shifter there is a small rubber plug. Remove this plug and use a #1 screw type extractor to remove the low range shift fork rollpin. Tap the extractor into the end of the rollpin, and with vice grips on the extractor pull and twist in a counterclockwise direction to remove the rollpin. It may take 2 or three tries to remove the rollpin. If you cannot get the screw extractor to ďbiteĒ, I had to drill out the rollpin, essentially shredding the rollpin inside the shaft. Then I punched what was left of it through with the 5/32 punch. Youíre going to have to go pick up another rollpin if you go this route. Pay special attention to the flats on the shaft when you remove it so you get it back in the same way. When you put this back together youíll need to reinstall this rollpin.

Give the input a slight tap and:

Remove the input gear out of the NP249. Itís pretty much the same process as described above. With a few exceptions.
The tailshaft is one(1) piece on the NP249. This is where to access the snap ring. And you won't have to remove the rollpin on this one.

The input shaft I pulled from the NP242 on the left. Compared to the input gear that came out of the NP249 which is going into the NP242.

Put it all back together in the reverse process with your new input gear in the NP242. Make sure to clean out the inside of the NP242 before you put it back together. Clean all the surfaces with your gasket remover or razor and be very liberal with your RTV application (LOTS). Make sure to tighten everything down. Make sure to add one(1) quart of ATF or Differential Gear Lube to the case before you crank it up. I chose to use some AMSOil. Good stuff. Adjust your shifter linkage for the new case and you should be ready to roll!

Hope this helps anyone interested in performing the swap. If you have any questions donít hesitate to ask. If you do a swap using my write-up as reference, please, email me and let me know. wesleyfree@hotmail.com. Good luck!

All information provided herein © 2010 KevinsOffroad.com. All rights reserved. "Jeep" is a registered trademark of the Chrysler Company.