1996 5.2 w/249 to 97 xj 231 swap

**JEEPERV89** · 12-13-2006, 06:21 PM

Im going friggin blind here looking at search after search for the info i need. Heres the scoop

Got a 1996 5.2 with 249. I have aquired a 97 xj 231 with the front and rear drive shafts. The xj tcase has a 23 spline input shaft. I have not pulled the 249 yet. This is the DD and in my line of work i cant just have it down for a few days while i sort shit out.

What else should I need. I mean do I need a new rear DS or not. Im not worried about the front right now since Im doing the swap for the 2wd option. What about this GD input shaft. If I am reading all this right this thing should just bolt right in. The 231 has 23 splines and no inner collar. The 44re that I assume is in my rig should have a 23 spline output shaft.

Everyone is talking about short medium and long shafts. I get the picture of what the difference is but how is it measured. Do you measure from the bearing retainer to the end or from the mounting surface of the case to the end of the shaft.

Any one have input about the 96 to 98 231 swaps or can point me to a url that has the info. Most of the swaps i have seen that have detailed write ups are pre 96 and all those guys hit brick walls with the inner collar and the gear cuts of the input gears.

**DJJordache** · 12-13-2006, 06:40 PM

according to my dealer parts list and some other swaps I have seen the 96-98 v8 has the medium input on it's transfer case which is the .840 AND the 96-01 XJ 4.0L 242 and 231 used this same input length of .840. this is measured from the tip of the input shaft to the bearing retainer cover on the transfer case.

measure the length of your rear drive shaft from the center of the transfer case side ujoint to the center of the axle side ujoint.
FYI mine is 31.5" on my 4.0L 42re with a 231 out of a 2000 XJ my rear drive shaft is from a 97 ZJ 4.0L 42re with a stock 242. MEANING that I have also heard of others who have swapped out thier 96+ 249 for a 96+ 242 or 96+ 231 and reused the rear driveshaft.

measure the length of your 96+ 249 and the total length of your 96+ 231 they should be "pretty" close

you "should" be able to just reuse your stock rear driveshaft and if your front one is not the CV style but instead the double cardain style then you can probably reuse that one too. the XJ driveshafts are probably no use to you since they will most likely be too short.

**Jim311** · 12-13-2006, 06:41 PM

I was thinking about trying to find a 231 out of a Dakota with a 5.2 and trying that personally on my 96.

**DJJordache** · 12-13-2006, 06:45 PM

isn't that the 231D or 231HD? IIRC those don't have a hole for the speedo gear right?

**Jim311** · 12-13-2006, 06:46 PM

Dunno, good question!

**DJJordache** · 12-13-2006, 06:54 PM

according to drivetrain.com few others on there but these are closest

the one with a speedo hole and the medium input BUT has 26 rear DS splines
1988-1993 NP231D
23 Spline input 26 spline rear slip output non-synchronized, fixed front yoke w/1.75" speedo hole, 840" exposed input shaft

with medium input and 27 output but no speedo hole
1996-1997 NP231D
23 spline front input 27 spline rear slip output, fixed front output yoke synchronized, w/o speedo hole, shift indicator above shift lever .840" exposed input shaft

**JEEPERV89** · 12-13-2006, 11:04 PM

OK first sorry for the rant above just frustrated with the information overload.

I measured the rear DS 34.5 inches. Noticed the 249 has a internal slip yoke and the xj 231 has a extrenal slip yoke with a black boot. Is common or am i just lucky.

**DJJordache** · 12-14-2006, 01:09 AM

Originally Posted by JEEPERV89

I measured the rear DS 34.5 inches. Noticed the 249 has a internal slip yoke and the xj 231 has a extrenal slip yoke with a black boot. Is common or am i just lucky.

I don't know for sure what the stock rear ds length is on a V8 44re setup....you should measure the 249 vs the 231 and they should be close. the 93-98 249 is internal slip and the 96+ 231 is external slip with that boot (I just used an old shock boot)

**NAFTEL** · 12-14-2006, 10:17 AM

my rig has this swap - 96 5.2 that came with the 249 swapped for a 231J - sizes are the same no problem. only problem was the shifter in the cabin - i also got a novak shifter put on and a terra low 4-1 kit so stock shift handle etc had to be replaced

**JEEPERV89** · 12-14-2006, 11:32 AM

Cool then sound like I go t the right tcase then. Im going to give it a good looking over on the inside befor I pull the 249. I was tinking of replacing the chain. What is the wide chain conversion. Is this a kit or a chain from a different truck?

**SirFuego** · 12-14-2006, 12:32 PM

I have a 93ZJ 5.2L that had a 249. I found a junkyard 93ZJ with the 4.0L and the 231. When we swapped it in, we needed to swap input shafts. We never bothered measuring the input shafts because it was obvious that they were different lengths. We just verified the spline count and gear cut.

If you got the metal tab that connects the shifter and transfer case, use the one from the 231 -- or else I've heard shifting in/out of 4LO is a PITA. My 249 and 231 had different length tabs. Using the tab from the 231, I have no problems with my shifting, so I didn't need to invest in an aftermarkey shifter.

My original front and rear driveshafts bolted in without problem.

**jaxonthorax** · 10-08-2007, 11:46 PM