Hello fellow enthusiast. I know I’m most likely beating a dead horse but I’m desperate and have tried everywhere.
This is a rhd lowered 2wd model just for fun. Nothing fancy we haul are Bantam trailer with it.
I rebuilt transmission and the only problem is that gear. I’m going insane all my builds are 4x4 so I’m at a loss. If anyone has any ideas I’m looking. I’ve even thought about having one made by a 3D printer and pressed onto the original steel section. Haha.
thanks y’all

 

I had the same issue with my rwd xj, most of the parts still being made are for the 4x4 models. There’s hope though, the gear pattern for a transfer case Speedo drive gear is the same as what would’ve been on your output shaft. I bought a drive gear for the 231 t-case and used a drum sander to bore out the ID so it would be a press fit for the splined sleeve from my original drive gear. I used a heat/oil resistant rtv between the two parts before pressing them together and letting it set up. The rtv is just to help bond what was left of the plastic splines and the knurling on the metal to keep it from slipping. I probably should’ve used JB weld or some other epoxy, but I had the rtv and limited time. It was a pain to do, but I’ve got a working speedo an cruise control now.

 

If you decide to do this, it’s a good idea to check the tailhousing bushing for excess play and replace it if needed. I got a 38mm ID bushing and output seal on eBay pretty cheaply. Be sure to check the diameter of your driveshaft slip yoke. They came in a few different diameters, and you want to make sure your replacement is the right one for the job.