242j (HD or not ) into WG 2.7crd

[lemioux@curbside]

Ok , i've been contemplating this for a while now ... and now that i put a U joint/double cardan sgaft on the front of my 2,7crd wj wg i realize that i have to do something with the transfer-case .. it has some play , it rattles and i've changed 2 shafts now thinking that the noises were from the shaft as without it it's nice and quiet ...damn it .
i read somewhere that KJ 242j fits easy in 2.7crd as the front yoke it's the same ( u joint one ) and the rear can get a "hack & tap" front rezzepa yoke adapted to the 32 spline rear output .
IIRC someone did this here too ...
So any info on this swap ? the shifter plate might not like the other positions but i guess that can be cut so the magnets can be moved by hand to N or LO ,, the rest of the positions can use the plate's 4HI position ( in 242j - 2wd, 4full , 4part ) .
So , any input here ? PICS , drawing )))) lets revive this forum a bit with fun mods.

[Adrian D]

KJ 231 all the way. You can find them with 32 spline rear output shafts. It's way stronger than the KJ 242. As far as I remember the center diff or the gearset in the 242 is much weaker than in the 231.

No need for anything updated on the shifter board for either options.

Bucin Pass, April 2021, 231 in 2wd mode, with all-season tires:



The road was almost empty, the amount of traction out of turns was surprising with open diffs. Switched it into 4wd and I could get it too fast for how well the tires handled snow braking.

[Classic Boy]

Originally Posted by lemioux@curbside

Ok , i've been contemplating this for a while now ... and now that i put a U joint/double cardan sgaft on the front of my 2,7crd wj wg i realize that i have to do something with the transfer-case .. it has some play , it rattles and i've changed 2 shafts now thinking that the noises were from the shaft as without it it's nice and quiet ...damn it .
i read somewhere that KJ 242j fits easy in 2.7crd as the front yoke it's the same ( u joint one ) and the rear can get a "hack & tap" front rezzepa yoke adapted to the 32 spline rear output .
IIRC someone did this here too ...
So any info on this swap ? the shifter plate might not like the other positions but i guess that can be cut so the magnets can be moved by hand to N or LO ,, the rest of the positions can use the plate's 4HI position ( in 242j - 2wd, 4full , 4part ) .
So , any input here ? PICS , drawing )))) let’s revive this forum a bit with fun mods.

You may need to swap the xfer case input shaft to match your trans output shaft splines and length.

[JoergM]

There is a way you can use parts of your old 247 transfer case and put it into a np242. Here is a video which explains this:

Transfer Case Swap for Beginners - Everything you need to know! - YouTube

However, this is for a petrol WJ and not sure if this works for the CRD. Be mindful that the splines of the hack and tap from IronRock Offroad for example does not fit I think there is a difference of 2 teeth or so. Not much but enough to not fit. So you still might need to do the exchange as in the video and then the follow the hack and tap or you get the more expensive NP 242J SYE Kit (https://www.ironrockoffroad.com/prod...j-sye-kit.html) this should solve your issue.

The reason is the transfer case position sensor. It is not present on the V8 so you can transfer the cone as of the np247. The position sensor is being used on the CRD however so you need to factor that in.

[lemioux@curbside]

That's why the kj 242, 231 have 32 spline outputs (front and back ) so the 247 front yoke (for double cardan fits , and IRO hack n tap 32 can also be made to fit.
And the input is the peachy 23 spline .84" all fits 2.7crd asapter (622 to 23 us NP 247..)

[Adrian D]

My NP231 was 27 spline front, 32 rear. Strange.