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241OR swap in a 2000XJ

bajabronco

NAXJA Forum User
NAXJA Member
Location
Reno, NV
I am starting the process of my 241 swap into my XJ tomorrow, - getting it ready for summer wheeling out here in CA. I am hoping everything goes smoothly, but I already face more work since I have the BDS long arm kit. With the BDS kit I will have to drop the whole front suspension in order to get the cross member out, which is a PITA! I have read a couple of posts on the swap, any key tips from anyone? I'll take and post lots of pics as things progress tomorrow. https://flic.kr/p/RVsBiR https://flic.kr/p/RVtDWK
 
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The swap is pretty straight forward. The only issue will be with the speedo sensor which I never did deal with but I was looking at Dakota Digital. I bought mine NIB, but that was 14yrs ago.
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I forgot to add that you'll have to do something about the outputs and driveshafts. I ordered mine with 1350 CV yokes and had TW make me some shafts.
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I didn't do anything but bolt it in. I didn't even have any shifter issues.
 
I took the old 231 out this weekend, and got the new 241 in, It is as pretty straight forward swap. I highly advise anyone who is getting a long arm kit, to NOT get one that does not allow you to remove the Tcase without dropping the whole front suspension. It adds a lot of time to the swap.

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The 231 came out, hardest part was breaking the hard to reach bolts loose! I lowered the tranny down as far as it would go so I could get better access to the Tcase bolts. As you can see the 241 is substantially larger than the 231 I had in previously
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I removed the old shift linkage, and then installed the 241, I initially tried to use a floor jack but that didn't work well, so I found the easiest way to do it is to lay under the truck with the tcase on my chest and simply bench press it up. I had a buddy with me and he simply helped guide it in.
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I recommend first installing your Tcase and then install your linkage brackets- if you go with a new one.

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I decided to go with a cable shift linkage conversion from Savvy Offroad. The kit comes with NO instructions so I used the Novak instructions as a guide, it is basically the same kit. The hardest part of installing the kit is having to pull up the center console, so you are able to pull back the carpet and remove the old shifter linkage and install the new cable bracket. I pulled my drivers seat to make access a lot easier.

Since I had a 2000 XJ, the speedo connector plugged right in, I did have to use a different plug and weatherpack connector for the shift indicator, Dorman 600-506. Pigtail - AC Delco PT724.

I still have the stock exhaust hangar bracket, I had to trim it to fit around the new, larger Tcase
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its a grate swap. if you drill new mounting holes you can clock the case and move it above the crossmember.
 
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its a grate swap. if you drill new mounting holes you can clock the case and move it above the crossmember.

Where are you going to find the room to drill new holes?
 
I agree, when I was doing the swap there didn't look like any way to drill new holes in the tranny housing that would enable it to mate up with the TCase. The part of the transmission housing where the bolts go through actually extend out from the housing.
 
I clocked mine and this is what I ended up with. Just drilled 3/8 or so clockwise on the flat pad and skid still fits. I did have to tune the floor alittle and will need to do it some more when I install my SFR trans mount instead of the polyurethane one I have now.

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why change out the polly for a SFR? I find the poly unit to be solid even with the low gearing.
 
why change out the polly for a SFR? I find the poly unit to be solid even with the low gearing.

Just trying to reduce vibration, sometimes it's hard to see in the outside mirrors when backing up.
 
I know your going to love it but, and I hate to even tell you this but they have a 2LO kit for it. :cheers:
 
37x12.5R17 BFG Krawlers with around 5.5" of lift, RE 4.5" coils and 1" spacer and Notch Customs flairs.The rear has some old, soft ass Zone 3" springs, a shackle relocation bracket and a 5" boomerang shackle. I am installing a longer boomerang shackle and moving it farther back in the relocation bracket.
 
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