NP242 front output stuck

[biedejk0]

I have a 1999 Jeep XJ with a NP 242 transfer case. Several months ago I put a 4 inch left on the jeep and dropped the transfer case 1 inch. Seem to be driving fine for a few months. I have no idea whether the lift is related to my issues, but thought I would mention it. Also, not sure if this is relevant, but it went from being above freezing to well below freezing in between the last time I drove it and now.


Tried to put it in gear last week and the front wheels were locked up. Took the front driveshaft off to try to determine if it was the differential or the transfer case. The wheels spin fine with the driveshaft off. The shifter for the transfer case seems stuck and I can’t move it.

The U joints on the driveshaft seem to be moving fine.

The output on the transfer case that moves the rear driveshaft seems to be working just fine.

Any ideas what could be going on here?

 

[Tim_MN]

Dropping the T-case puts extra stress on the poorly designed shifter mechanism. Can you shift it by disconnecting the floor shift lever, and using the Range Lever on the side of the T-case?

Shift mechanism adjustment or worn mechanism bushings, and worn out internal shift fork tabs are logical suspects.

Consider one of the aftermarket shift mechanism upgrades.