I just had it out in the snow and know for sure that its engaging most of the time. Its just that sometimes it doesnt. This time the light on the dash was flickering real fast and then it stayed on.

 

Not to hijack, but my problem is almost identical to his in every regard but this, my 4x4 lever is really hard to move.

 

Then you need a transfer case linkage adjustment...
Mine is kinda silly like that too, only it over-shoots 4HI...
Easy fix, all you need is one wrench and crawl under the Jeep...
You could also take it all off, and clean it up, I know I have to do that almost yearly on mine, just to keep it free of corrosion and other crap.

 

As always...how?

 

don't worry what the light is doing its just a switch that tells you what position its in unless you have a disco axle
you should be able to feel if its in 4x4 or not

 

x2, I don't trust the indicator light one bit. I always drive on it a bit before I try this, but I try to slip the tires real quick. Unfortunately, the little 'burnout' seems to get my 4wd engaged...not pleasant.

Okay so very similar problem: The only difference is that my 4wd selector seems to hardly want to move at all, I can occasionally get it to pull into position when I come to a complete stop and then give it a good tug, but that's about it. Other than the selector issue, my light rarely reflects whether my 4wd is engaged or not.

 

IIRC, loosen the nut that connects the linkage to the shift rod on the side of transfer case. Manually rotate the shift rod on side of transfer case so the transfer case goes into 4LO. Sit in the drivers seat move shift lever into 4LO position, then crawl under and tighen down the nut on the linkage. There might be an easier way, but it should work.

And my 242 was difficult to get shifting at first, I guess the PO never used it, and now that I use it, it slides in and out nice, not as good as my 231, but I'm working on that. Might also want to try a fluid change if it hasn't had one in a long time...

 

I have had many jeep and every one shifted different

but best way to shift into 4hi is in neutral 4low neutral but if it shifts hard try it in drive let it roll forward very slow and sift it into 4low

 

the one thing that every T case has in common is that lack of use makes it harder to shift into 4x4 and low

my best advise is to use it ones a week

 

I usually don't rely on any electrical component, since my main 4x4 is an old CJ3B. I can feel it engaging most of the time, but in some cases it isn't. Maybe It wasnt used much which is what some people are saying. I do notice it is working better after about a 4 mile drive in "full time". Maybe its freed itself up a bit.

Quick off topic question: is it very hard to clean the neutral safety switch, and does it take a bit of time?

 

there should be a wright up on that in the tec section

 

disco info
https://www.cherokeeforum.com/f51/mystery-vacuum-disconnect-dana-30-a-6966/

 

Thanks, for some reason I couldn't find it I think I'm a little slow

That might be my problem, It might be sticking or worn out I suppose.

 

good wright up on fixing the NSS
http://jeepin.com/features/nss/index.asp

 

THANKS!!