I got a 95 xj and I've read all the fourms about the NP 242 getting stuck in 4wheel drive. Here's the thing I've tried it all. Its not a linkage prob cause it took a rod and hammer to get the transfer case out of 4lo and into full time 4 ( so I can still use it on or off road until I fix problems). Got it high centered and that's when it started. Before that it shifted between gears perfect. Any ideas? I'm convinced something in the tcase is bent.

 

You have to put the transmission into Neutral before you can switch the transfer case through Neutral. Its in the owner's manual. If the input planetary is loaded up, its extremely difficult to switch between the 1:1, N, and 2.67:1 positions of the planetary drive. Just put the transmission in Neutral and unload the drivetrain.

 

That's not the problem. I've had it on jack stands with all 4 wheels off the ground. I got it into 2wd by putting a rod on the shift arm on the tcase and hitting it with a hammer. I've since put it back into full time 4wd. The problem is inside the tcase its not in a bind.

 

I know the problem is inside the transfer case. The input shaft from the transmission spins a planetary gear assembly at the front half the transfer case. The main shaft connects to the planetary with a little collar that moves in and out as needed. In the 2WD, 4Hi, and 4FT positions, the collar engages the 1:1 position on the planetary. In the 4Lo position (only) it moves to the 2.67:1 position. In Neutral its between the two positions in a dead spot. If the input shaft from the transmission is loaded up, or if the mainshaft to the axles is loaded up, its extremely difficult to make the collar move.

If it will not move with everything unloaded and relaxed then the best guess is that the shift collar is damaged somehow.

 

Guess I'll find out once I pull it apart. It won't shift in or out of anything without ALOT of force.

 

Have you been shifting it like this?

Here's how the factory suggests you shift the transfer case and I've been doing this since these things were new and I worked at the dealership. Quoted from the owner's manual. The suggestions in CAPS are mine.

"To engage, shift the transfer case lever from 2H to 4H while the vehicle is moving at any legal speed". I LET OFF THE GAS, THROW THE LEVER, TAP THE GAS AND LET OFF.

4L position: " To engage, slow the vehicle to 2-3 MPH , shift the transmission to Neutral, then shift the transfer lever to the right and pull firmly rearward to 4L".

TO SHIFT OUT OF 4L, SHIFT THE TRANSMISSION INTO NEUTRAL WITH THE VEHICLE STOPPED, SHIFT THE TRANSFER CASE LEVER TO 2H, THEN THE TRANS TO D IF YOU HAVE AN AUTOMATIC, OR INTO FIRST GEAR WITH A MANUAL, AND CONTINUE ON.

Revised 11/20/2014

 

That seems likely, considering the 242 hangs low. Being high centered I'm sure the case was impacted.
But I cannot speculate on the internals and what that impact and the weight of jeep might have done to it. That is Ehall's department.

 

Possibly. Skid plate?

Bent linkage? Mounts damaged?

Lots of variables I would look into before pulling it apart..........

 

I've removed the linkage. It takes a BIG hammer and rod at the transfer case to move it between any of the settings.