Jeep Wrangler TJ and LJ to Jeep JK 241/241OR Transfer Case Swap Kit

Barnes 4wd has developed this kit to make adapting a 241 or 241OR transfer case from a 2007-2018 Jeep Wrangler JK or JKU into a 1997-2006 Jeep Wrangler TJ or LJ a simple bolt in conversion.  The JK 241 or 241OR transfer case is stronger unit, it has larger 32 spline outputs, a wider chain, and it also features a fixed rear output eliminating the need for a slip yoke eliminator.  The 241OR from JK Rubicon models also include a low range with 4:1 gearing, providing a much lower low range than the 231 2.72:1 gearing.  All of the components in this kit will bolt on, no modifications to the transfer case are required, and you do not have to disassemble your transfer case for installation.  This kit includes provisions for a speed sensor on the rear output, a new shift lever, a clocking ring, and a seal extender for the rear output of your transmission if required.  Be sure to checkout our Tech Article for more information about this swap.

Installation notes:

• This kit will only work with 1997-2006 TJ and LJ Wrangler models with a transmission with a 23 spline output shaft
• A 23 spline input JK 241 or 241OR transfer case is required.  Generally this will be all manual JK models 2007-2018 and automatic models 2007-2010.  Be sure to confirm your donor case is a 23 spline female input with a stick-out length of 1.37" measured from the mounting face of the transfer case to the end of the input shaft
• Driveshaft modifications are required.
• The front and rear outputs of the 241 will need to be swapped to a companion flange (Parts Mike part# DM4500GK rear, part# DMG4600GK front)
• All bare steel components will need to be painted or powdercoated during installation
• Transfer case shifter adjustment or modifications will be required, an aftermarket cable shifter is recommended
•  The speed sensor will need to be purchased separately.  It is an off the shelf speed sensor for a 03-06 TJ or LJ Rubicon (GPD part# 1815604)
• If speedometer adjustment is desired for tires or gearing a speedometer signal modifier will need to be used (SpeedoHealer, Dakota Digital Speedometer Adjustment Module, ETC.)
• 97-98 models may need the chassis side speed sensor connector (GPD part# 1P1080) swapped or the speed sensor wiring spliced in
• The range switch in the transfer case will need to be swapped if the dash 4wd indicator light is desired.  Switch: Wells part#1S4219, Connector: Wells part#1P1796
• The JK 241 transfer case is clocked lower from the factory than the TJ 231.  The provided clocking ring will allow you to rotate the JK 241 transfer case up to the same rotation as the original TJ 231
• The JK 241 is a larger transfer case than the TJ 231 some clearance to the transmission tunnel may be required or a body lift
• The JK 241OR has a larger planetary section, the TJ transmission mount may have the be trimmed for clearance
•  TJ and LJ models were supplied from the factory with various transfer case input lengths ranging from 1.2”-2.1”, the JK 241 has an input length of 1.37”.  Sufficient spline engagement will need to be verified before installation.  A spline engagement of at least 1” is preferred but is ultimately up to the installer’s discretion.
  

Tech Article: Swapping a JK or JKU 241 or 241OR Transfer Case Into an Older Jeep Model