The link didn't work earlier when I tried it, but it is working now.  What you are telling me is that the input shaft can be removed from the planetary gears and then I should put the longer input shaft and input gear from the 249 into the planetary gears from the 231 and then reinstall it into the 231? If that is what you are saying then someone left that out of the descriptions I have read.  If I understood what you told me and what I read then I am going to wait and take a closer look at the input gears. I really appreciate your help on this.  Your are the only person I have talked to who seems to know what you are talking about.  

Here is what an input gear removed from the planetary gear set looks like.

 

I saw that picture on your link.  I have to say reading about the input gear and looking at the pictures has set off a light bulb in my head.  I will not be able to mess with the transfer case again until late Tuesday, but I will update you on what is going on.  I am going to take a closer look at the input gears and make sure they are the same cut.  If they are then I am going to try to put the 249 input gear into the 231 planetary gears and see if that fixes the problem.  If they are not the same cut then I will have to order the correct one.  I say all of this because I remember when my stepfather and I were trying to figure out what was wrong he mentioned that the 231's shift hub did not seam to fit the planetary gears of the 249 was well as he felt it should.  This makes me think that you hit the nail on the head.  I will have to take a closer look at some things.  Give me some time and I will update you.  Thank you for all of your help so far. Talk to you again later in the week.  

Today we found out that the input gears are different.  One is the new cut and one is the old cut.  I just decided that I am going to send the Tcase back and ask them to send me a new 231 with the long input shaft and 23 spline that way I should be able to bolt them in directly.  I am tired and frustrated so it will probably be a week or so till I can complete the swap.    

ratts..  

Just and update.  The company sent me the wrong case again.  They sent me another medium shaft Tcase out of a 95 Grand.  They are supposed to be sending me another.  If I recieve the wrong one again then I will find another one elsewhere.  

Novak will supply you with the right input gear if it comes down to it. I think they will exchange the one you have for the one you need. I don't think they charge the whole $150 dollars that the dealer would charge you, but I don't know the cost. Call them as a backup (435)753-2513.  

Does anyone know the part number for the long 231 input shaft with the late cut?  

It's not an input shaft, it's an input gear. Did you call Novak?? They are very helpful!  

Yes, I called them earlier today and I have one being shipped right now.  Hopefully it will be here Friday.  

So, let me see if I have this right.

Your Grand Cherokee 249 TC has/had a 23 spline, long, old cut, input gear.

You have aquired a new to you 231 TC. The input gear is not a 23 spline long. But, it is a new cut. Meaning the 231 planetary gear set and the ring gear in the front case half is of the new cut variety.

So, you have a 23 spline, long, new cut, input gear on it's way.  

Sorry to hear that you are having so many problems. ftgiles is correct on the input shafts.

If this seems like too much trouble, I have V8 ZJ heavy duty 231 conversions for 950.00 (no core charge)

I include the 4x4 switch, and correct sector that allows the use of your stock linkage. Darin 434-284-1315  

MountainGarage:
Sorry to hear that you are having so many problems. ftgiles is correct on the input shafts.

If this seems like too much trouble, I have V8 ZJ heavy duty 231 conversions for 950.00 (no core charge)

I include the 4x4 switch, and correct sector that allows the use of your stock linkage. Darin 434-284-1315

Can you give a little explanation about the compatibility between the ZJ 249 shift linkage and the 231 sector.

This has also been a point that I have been trying to get nailed down in this thread.  

I did the same swap. you need to use the 249 linkage and it will work. Even better use the novak #sk2x shifter and it will work great. gets rid of all that linkage very positive shifts easier to adjust  

Ftgiles you are exactly right.  I will have it here by Friday.  The issue with the linkage is simply an adjustment that has to be made under the grand.  I will see if I can snap a pick or two when I finish the swap.