Need emergency 231 sye help.

[matt0106]

I just recently installed a Rugged Ridge SYE on my 231. I followed the directions and put it all back together. Now it won't shift into 2wd nor will the Jeep move in 4hi or 4lo. It also makes a grinding-ish sounding noise when I shift my transmission from any gear into park. I'm confused as to why all this is happening. I just need help trying to figure out why all of this is going on. This is my daily driver and I'm tired of having someone else drive me around. Any help would be appreciated. Thanks in advance guys.

Info:
*4.0 I6 engine
*AW4 auto tranny
*NP231J transfer case
*Rugged Ridge SYE

P.S. I had to cut the shift fork rod down, but that shouldn't be the problem, it's not hitting the output housing.

 

[Tim_MN]

When you say "it wont shift", do you mean from the floor shifter, or do you mean the range lever on the T-case will not shift it ? Did you install the SYE under the Jeep or on a workbench ? Did you check for correct shift operation after installation of the SYE ?

It might be logical to wonder if you may have re-assembled the T-Case incorrectly, installed/adjusted the 4x4 shift lever mechanism incorrectly, or that the poor quality control at Rugged Ridge built another out of specification SYE kit.

 

[matt0106]

It wont budge going into 2wd, from the floor shifter in the cab. Under my jeep. Sorta, I finally got it all put back together today, and went to go check the shifting and that's when I noticed.

I was thinking that may be the problem but I don't know exactly what I put in wrong if I did. I haven't adjusted or removed the shift lever mechanism. And everything about the SYE kit seemed to be in perfect condition.

 

[souske]

Will it shift using the tab/ lever underneath, without the linkage attached?
If not, you missed something on reassembly, easy to do.

 

[matt0106]

I don't know yet, I haven't tried to shift it that way yet, it's late here.

 

[unhitched]

mine did that when i put it back together... I had to remove the tail shaft cover, shift into 4 low and then reinstall the tail shaft cover. there was enough play in the mounting bolts that they shifter rail misaligned enough to where it would not come out the hole in the back

 

[matt0106]

I put it into 4lo before installing it and left it there the whole time. I only shifted out of 4lo after I had everything back together.

 

[matt0106]

Alright guys, here is an update.
I had my mom shift the transfer case for me while I watched. Shift fork rod was not moving. Took off the rear half, and it didn't move. I had to guide it into the hole in the back half of the case. So, I think I'm going to have it in 4lo, put everything how it is supposed to go, then have someone shift to 2wd and guide everything into place. Then without sealing it put the rear half and output housing on, and put all the bolts back in, just to "mock it up," and have someone shift and cycle through 2wd-4lo a few times to check if its all working. If it all checks out, I will leave it in 2wd, then take it all back apart. Not touching any internals with it all working, I will then put gasket maker on everything and put it all back the correct and final way. Sound good?

 

[matt0106]

Also, here are some pics for ya'll to look at and let me know how everything checks out. I only removed the main shaft and didn't touch the two shift forks.
Here is the shift fork and hub thing:

Here is the shift fork pin and range selector pin with the cam:

Here is the main shaft with everything on it:

 

[rockchucker]

The one thing that gets over looked is a spring on the inside of the t case, if you miss this spring it will not shift correctly. We put mine together twice.

 

[matt0106]

Yeah, it was put back. I think it has something to do with the shit fork rod. Gonna check it out on Thursday.

 

[stumpXJ]

The rod has to be a certain length, other wise it hits the fill plug area on the new rear housing. I had to cut mine slightly. It mentions this in the directions.

 

[matt0106]

Yeah, but, I had already cut it once before, and it ended up being too long still.

 

[stumpXJ]

So....you need to cut it more? what was the measurement?

 

[matt0106]

Yeah, I cut it down more, I don't remember what the length was the first time I cut it.