If you search around here and other Jeep forums on the net, you'll find this is quite a common occurrence, especially when the vehicles accumulate high miles.
Anyway, I shopped around for a new VC - turns out it would be cheaper to swap in an entirely different transfer case, namely the Selec-Trac (NV-242) t-case. The Selec-Trac is highly desirable because it offers a 2wd position, as well as 4hi part-time, and 4hi full-time, and 4 low positions. This is the route I will be going, as I like the 4hi full-time position. Fortunately the 242 does NOT utilize a VC, so you don't have to worry about any more VC failures.
Many people have swapped out their NV-249's with the NV-242 or NV-231 (Command-trac). It makes more sense financially, as you will have a reliable t-case for roughly the same price to replace the VC in your 249. You'll also have the piece of mind of knowing you won't ever have to deal with any more VC failures.
You can do a search on here and on the 'net for "249 242 swap" and you'll come up with some websites that will go into details about this swap.
I have purchased a 242 from an XJ (Cherokee) for $250, and once I get some free time, I'm going to yank out that crappy 249 in my ZJ and swap in that 242.
Hope this helps you out! Good luck and feel free to ask any additional questions about this swap.
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Darren Asuncion
[email protected]
'94 Flame Red Cherokee Sport, 4.0L, AW4, NV231, Chryco 8.25" 3.55, Rusty's 3" lift, JKS Quicker Discos,