Here is my story....1998 jeep xj 145k miles. Few months ago, xj started slipping out of gear and grinding while I was driving. It would slip back in after I let off the accelerator, and it wouldnt happen again for a day or two. I lived like this for a few weeks, but then it got worse, and I took it to the nearest shop. They drove it, made it make the sound, got under it, drained the transfer case, and showed it to me. There was plastic pieces just falling out of the T-case, and they quoted me $2,400 for a replacement. I figured I could just find a junkyard t-case, but that didnt happen. rebuilt np242's were over a grand, so I decided to do the t-case rebuild myself. I got the t-case off and on my work bench and took it apart. here are the problems I have found.
1. found the mode shift fork to be ground down to a stub on one side due to the plastic pads being desinigrated (bought replacement for $50)
2. the T-case lacked the seal plug underneath the linkage (making it easy to remove the forks, which I had read was supposed to be a PITA)
and now I have a few questions on what parts to replace, and how to reinstall everything.
Question 1. How can I replace or repair the "roll pin" and the seal plug that is missing, and is it necessary?
Question 2. How do I reinstall the forks so that the shifter rooster tail is in the correct position?
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04-03-2014, 11:29 AM
