98 TJ 2.5 auto transmission transfer case into 97 TJ 2.5 with a manual transmission?

You can but keep the output shaft on the transfercase you take out to swap into the one you are putting in. I cant remember exactly but I believe the manual one is a little bit longer.

If it was a transfercase out of a 4.0 and into a 2.5 then no, the output shaft splines are different (23 vs 21)
 
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You can but keep the output shaft on the transfercase you take out to swap into the one you are putting in. I cant remember exactly but I believe the manual one is a little bit longer.

If it was a transfercase out of a 4.0 and into a 2.5 then no, the output shaft splines are different (23 vs 21)
When I do the shaft swap should I change or replace anything while it is open?
 
It would be a good time to install a SYE kit while you have it out, if you want/need one.
A Savvy or Novak cable shifter would also be easier to install while you have the whole assembly out.

Might be worth opening it up early if you have time and checking the condition of all the parts. Then just order anything that looks off. I believe there are procedures in the factory service manuals of how to check and replace parts
 
Check the chain out and replace if needed. Otherwise you could change the Speedo gear if needed, and the output shaft seal if needed. The 231 is actually a pretty robust tcase. Most likely the internals are fine
 
Ok so I am pulling apart the donor 231 and ran into my fist issue. There are 2 snap rings I can not remove. I am guessing there is a special set of pliers to use. I have the one for snap rings with the hole but not this type. Can someone tell me what I need? Plz see photo

snap ring.jpg
 
I modified the removable tips on my pliers to grip the ring enough to remove it. A pair of flat head screw drivers can also work
 
I modified the removable tips on my pliers to grip the ring enough to remove it. A pair of flat head screw drivers can also work
not going to remove it with screwdrivers, way to strong a clip[ and do not want to damage anything. . These are external clips on the shaft. 1 is down deep. There must be a tool to remove them just do not know what they are called and where to get it.
 
not going to remove it with screwdrivers, way to strong a clip[ and do not want to damage anything. . These are external clips on the shaft. 1 is down deep. There must be a tool to remove them just do not know what they are called and where to get it.
You need External Snap Ring Pliers. Could also be called C Clip or Lock Ring. You need the kind with flat tips.
download.jpeg
 
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NAPA has a good selection around here. The snap ring pliers I have can operate as lock ring pliers and open up like that with a flip of a switch