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This is the VSS that came with an NP241 I bought from someone upgrading to an Atlas. He said that it plugged in directly to the wiring harness on his Jeep, but I can't find a plug or pigtail to match this oval shape. Most 3-wire plugs I've seen have more of a rounded rectangle shape than this...

Hey all, I've seen a few discussions around on the topic, but not my specific questions. I'm going to replace the NP231 in my 06 LJ with a NP241 from an 04 Rubicon. I'm also working on a tummy tuck and I already talked to someone at Tom Woods about a custom rear DS at my final length to go...

You'd need to also run a flip kit, right? Is that additional length?

Thought about that one too. $1000 for the box and then: 6 pinion planet is about $250, and I'm not sure how much of the other stuff I could get from a spare NP231. Would also need a shifter (cable shifter - $170). $1600-1700ish total. Would be a much cleaner setup I think.

Yes, I do have an LJ. I'd have to figure out what the final length would be 231 + half-ish 231 - SSYE...

Why is this, and is it the same for manuals and autos? Not sure if the different gear options make a difference. And am I off my rocker here? On paper I could build a 231/231 doubler for less than finding or building a single 4:1 tcase, but is that more trouble than it's worth?

On the point of throttle control - I've also seen some people swapping out their throttle return springs with something stronger so the extra resistance keeps you from accidentally going to hard on the gas pedal (or at least that's what I think the reason is). Is that a reasonable modification?

From what I've seen, people recommend upgrading to the 6-pinion planet in the second t-case, but stock is fine for the first/doubler.

Gear ratio comparisons: 3rd gear in low is about the same as 1st in high, and 5th in low is about the same as 2nd in high. I didn't think of that until after the last time I was on the trail and I kept switching in and out of low and my shifter was binding a bit. Wish I had thought of it...

So one option would be to use the Rock Box DIY kit and the LoMax 4:1 gears, which puts you at $2100 (as opposed to finding a used NP241, which are selling for nearly the same price). You'd also have to get at least a new rear driveshaft because of the length difference - I'm not sure if the...

So anyway... t-case doublers.... What I'm hearing pretty consistently is that I should regear first, then worry about doubling my transfer case or any other low gearing option.

Why not? 4th gear in low would be kind of like the final gear ratio of 1st in high... ish.

The chart is for 1:1 (5th gear in my case). Right now in 6th gear (0.84 overdrive) I can do 70 at 2235 rpm. That would go up to 2924 with 4.88 gears. What's a safe max rpm for continuous highway usage? I don't drive it a ton on the highway, but I don't want to lose the ability to do so.

Ok, so according to this chart, I'm less than ideal with 3.73 and 33s. To get back to stock (LJ came with 30s originally) I would need to be at 4.11 gears, but that's hardly worth doing for the cost and effort involved. "Best mix" would be 4.27 gears, but that also seems like only a small...

How do I find your build thread?

I can see the hand throttle being helpful for ascents. For descents, I think learning to ease the brake while feathering the clutch is going to be the key, but that's so counter intuitive to how we typically drive manuals. Normally we're afraid of stalling out so its either rev up or clutch...

Last time I went offroading I realized I need to learn better throttle control. I've driven manuals my whole life, but always with low-torque, higher revving 4cyls. My habit is to rev the engine to keep from stalling while engaging the clutch, but that's not great for rock crawling situations...

Ok, so even if it doesn't improve the mpg, what you're saying about 3.73s being undergeared agrees with the points about the engine needing to be pushed harder even if its running at lower rpm. I had been thinking I might be able to get away without regearing, but if I do go that route I will...

Good to know. Both the total cost and that regearing should be done first. Thanks.

Better gas mileage? I understand the other two benefits, but that part is counter intuitive to me because the rpm would be higher. But if it will be better, great!