Well this afternoon I went and picked up a new transfer case for my truck (there was nothing wrong the old one). A guy had it posted on craigslist for $100.

DSCN0342.jpg?t=1254605173

DSCN0343.jpg?t=1254605203

DSCN0344.jpg?t=1254605217

Yup, you read that right... its an np242J... the all wheel drive transfer case. It has 5 positions:

2wd
4x4 Part Time
4x4 Full Time (AWD)
N
4Lo

I had to go with the jeep version because the few years they put them in Dodge trucks (np242D), they had no speed sensor hole. Unfortunately, it has a 21 spline input on it now, but the input shafts between the 231 and 242 are interchangeable, so I'll put my 231 input shaft in it and bolt it to the back of my transmission. The other odd thing about the 242J is that the shift pattern is opposite of the 231D, so I'll have to fabricate a shift lever/linkage and make a new guide plate to support the extra positions.

I'll keep this post updated on the progress I make for anyone else who wants to make their truck all wheel drive.

 

Cool! Not a bad deal! How is the size and weight compared to the 231. Off hand since you got your 231 still in the truck.

 

Well I don't remember how heavy the 231 is, but the 242 is honestly not that much bigger or heavier. Lol, the nv3500/242 assembly will still be waaaaay lighter than the 46rh/231 that my truck came with. I'll let you know for sure the size/weight difference when I have them side by side.

 

Thats nice, cus the 4500 is HELLA heavy. Im 6'3" and pretty strong and I can just barely carry it 10 feet at a time. I highly doubt I could even lift the 241 and 4500 together, and would rather not have the hernea it would most likely give me.

Let me know how it works. I have to go get a 242 from a yard next week for the jeep. IF you want me to jack the linkage assembly for it I will.

 

Interesting, didn't realize the AWD case was selectable...

 

Yeah, I was hesitating on going to AWD cause of the poor gas milage, but when I found out you could run it in 2wd when you want to I was all over it. So when it's sunny and the ground is dry I can run 2wd, when its raining or snowing (not that we see much snow around here), I can run AWD, and offroad I still have 4x4 and 4Lo.

 

Yep, 2wd, 4hi and 4lo are a must. I'll be interested to see how this works out for you.. I assume our trannys have a 23 spline output?

 

Here they are next to each other...

The 231 is on the left and the 242 is on the right. Interestingly, the 231 is 19.5 inches long, and the 242 is only 17 inches long. But the 242 is a lot beefier looking as you can see. Most of the length difference is the rediculously long tailhousing of the 231. Also the front output shaft sits slightly further back on the 242, but with the front slip shaft it shouldn't be an issue. They are about the same width from the center of the input shaft to the center of the front output shaft.

DSCN0345.jpg?t=1254613821

I can say they weigh close to same as they sit in the picture (not enough difference for me to be able to tell without a scale), but the 242 is empty and the 231 is full of fluid, so the 242 is definately heavier.

 

Lol, I'm interested to see how it works out too! Mostly what it will be like to fabricate the shifter linkages and make (or get a jeep) guideplate for the shifter, since there are 3 positions in front of neutral instead of 2.

Yeah, our trannys have 23 spline, and the input shaft is shorter on ours than the 42 and 46rh (I remember that from my transmission swap). So basically, I have to use MY 231 input shaft. Skyshark is sending me his 231 input shaft for the automatics from his blown up t case so I can turn around and sell my 231 for someone to put behind a 42 or 46rh.

 

Sigh. You volunteer for projects like I do.

It may interest you to know that according to my latest research your idea about the NV4500 will work. I just need to find a bellhousing and flywheel and Ill test it out for ya.