t-case rebuild problems

jeepxj91'

NAXJA Forum User
Location
Fresno,CA
well ive been trying to rebuild my t-case the last month or so along with a sye kit. right now i have 242 in my jeep and im switching to a 231. now we ran into a problem today. when i shift the lever on the t-case into 4wd it works perfectly but when o shift it to 2wd the gear is still hitting like it were in 4wd, does anyone know what the issue could be.
 
on the SYE tailcone there is a cap that caps the end of the shift rail for the 4x4...

some of the SYE kits instructions say to trim the shift rail by something like 5/8" to make sure it doesnt hit this cap...

double check that...
 
yea ive figured that one out but i dont think it will affect how the shifter will sit on th egears themselves. just want to figure out why its doing this before i cut anything.
 
the cap on the SYE cover gets hit by that rail, and that rail being attached to the shift fork wont allow the gears to shift...
 
You did adjust the shifter to the correct position, right?
Dumb things can give big headaches, and be simple fixes.
 
Harlee&Tahoe said:
You did adjust the shifter to the correct position, right?
Dumb things can give big headaches, and be simple fixes.

yea i think this maybe the issue but this is the first time im rebuilding it so its all new to me. if anyone in fresno wants to help me please message me of something cause ive had this t-case for almost 2 months now and invested almost $700 into it. the help would be appreciated. thanks andrew
 
Loosen adj. nut
move shift handle to 4lo
put 4mm spacer behind handle and shifter track? (can't think of proper term at the moment)
adj. x-fer to 4lo
tighten adj.

Good luck with new 231
 
no i have not been able to but im supposed work on it tommorow morning. so we shall see. things always seem to not work out with time on this damn thing, hopefully it will tommorow.
 
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