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Durango transfer case swap?
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=3&t=83983		 Page 1 of 1
Author:  u2slow [ Fri Feb 05, 2016 3:53 pm ]
Post subject:  Durango transfer case swap?
I'm looking for a Select-trac (242) tcase to put in the KJ. The Durango version looks like a good candidate because the rear output looks just like my current 241's output... so I should be able to keep my existing driveshaft. Supposed to have the 6-gear planetary too.

Anyone know if the KJ front yoke swaps over?

Image
Author:  pontipine [ Sun Feb 07, 2016 8:53 pm ]
Post subject:  Re: Durango transfer case swap?
You might be able to find a 242hd with the round flange like the KJ. Dakota and Durangos and other V8 trucks would have this
I looked into this a while but had second thoughts. I was told the 6MT does not play nice with the center differential. I have noticed some other KJ owners with manual transmissions so I guess it can be done. I expect you will feel a bit more driveline lash than with the 241.
Author:  u2slow [ Sun Feb 07, 2016 9:33 pm ]
Post subject:  Re: Durango transfer case swap?
I'm reading on other boards the 242 only has a 32 spline front output. If that's true, swapping the cv cup yoke over shouldn't be a big deal.

I measured my kj241 at 17.5" from front face to end of alum taicone. There's at least 3 different 242 output styles. Two of them differ by 1.5". One of them is supposed to be 18.5" long.

There's enough XJ guys running a 5spd and 242 without complaints. I think its more an example of 'the factory didn't do it because....' speculation.
Author:  pontipine [ Mon Feb 08, 2016 5:53 pm ]
Post subject:  Re: Durango transfer case swap?
That's good to know!

If I were doing the swap I think I would go with the longer version. On my setup it seems like the slip yoke sticks out way to far out of the transfer case. Which one is the longer one?

There are around 3 different length slip yokes available from Spicer so there would be some room for adjustment. I went with one that was slightly longer when I replaced my sloppy old one. I can look up the part numbers if anyone is interested. They are pretty common used by multiple manufacturers.

Now if only some one would figure out how to get 2wd low working in a 241 (non rubicon) or a 242....
Author:  u2slow [ Thu Feb 18, 2016 2:34 pm ]
Post subject:  Re: Durango transfer case swap?
I went and saw a Durango 242. (Same as pic in earlier post) It measured 19" long (front face to end of alum ext housing). My KJ241 measured 17.5". I picked up a '91 XJ242 instead. It comes in at 17", but has the smaller 27-spline output.

Des the KJ242 has the accordian style rubber boot? Its really no different than the alum tailcone style. All it does is make a seal. The drive shaft it still entirely supported by the tcase output shaft. Only real difference is one is lubed by grease and the other by the ATF in the tcase.
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