brucet

Hi. I have a 1995 XJ 4.0 Automatic and have been through the mill finding a used tcase cause mine was blown. I got one finally, 23 spline input, right output shaft type but when I go to install it there's about a 1/2 inch gap between the housing and tranny and it just won't go! What am I doing wrong? Am I missing something? I've bench pressed this thing about 5 times now out in the 20 degree weather and can't see the problem. It's getting a little tough for this 60 year old guy. Please help if you can.
Thanks
Bruce

djritter1122

have you tried turning it while your installing it? the splines might be a little off.

OverlandZJ

In addition to the input gear spline count you need to match up the length. Sounds like yours replacement is too long for the Jeep.

What is your replacement out of.. model/year.

1995XJ_Sport

where are you located? maybe someone on here is close by and can come give you a hand, If your close I would.

tj40

it helped me to have the trans in neutral

Mike1998XJ

Compare the old one to the new one. Splines and lengths.

brucet

Thanks. The only thing I didn't check was the length of the input shaft. Pulled it out again and the input shaft is longer than the original. Also the vacuum switch is different on the replacement as it has 4 pins versus 2 on the original. Is there any way I can "make" this fit? Can I just swap the vacuum switches?
Thanks
Bruce

skookxj

honestly it would probably be less of a headache for you to just try and find one from the same year .....that would solve both your problems of harness and shaft length....(giggity).....thats the best i can say

captainwoot

I don't know how handy you are, but you could possibly change the input shafts... or have a local trans shop do it for you

OverlandZJ

There should be no vacuum switches on a 95 XJ transfer case. Does the Jeep have an NP231 or NP242?

Gonna need the production date off the replacement transfercase. Your best bet may be opening up both transfercases and swapping the input gear.

Gotta be careful here though as the input gear planetaries had a gear cut change around 95.

Where are you located?

ktmracer419

you got a 5 speed case

you need an auto case

brucet

I did some measuring and found that the longer shaft would fit all the way in on the tranny spline but that the interference is a shoulder inside the tcase input gear! The yard I got it from said "just break it off" which sound kind of extreme and I'm not seeing a good way to do it either. Anybody heard of this as a fix?
Thanks
Bruce

fantic238

That "shoulder" should be the input pilot bearing for the shaft. There are 8 different input gears, all 23 spline, listed in the parts catalog. Probably you can swap the two gears with the bearing. Lets see some pics.

brucet

I finally put a later unit (5209 8480 mfg 3/96) with a live output shaft design in (the original was a tail cone output shaft type 5209 8487 mfg12-21-94). It fit and there was no interference with the input bearing. The original drive shaft fit as well and I used a shock boot from AZ as the dust boot for the live shaft design. Thanks for all the help!
Bruce

Desert Rat

Props to Bruce, kind of rare around here that someone lets us know the outcome/solution to the origional problem and gives thanks to everyone trying to help them. Way to be Bro!