Having problems with a 231 transfer case.

So my original case was making a grinding noise and after multiple attempts to fix it, I gave up and bought a used 231. I had to swap the input gear, speed sensor, and shift indicator, but aside from that nothing else was changed. I put it all back together, but now I’m not so sure I did it right.

After I installed it, I discovered it’s stuck in neutral and it won’t shift out of it. The lever moves maybe about half an inch before I can feel it binding up. I’ve hit it with a hammer and moved the driveshafts and it’s still stuck.

I’m trying to think of what I might’ve missed, but I can’t come up with anything. Any help is much appreciated.

it would be good if you still have the old case fairly intact, as you can dismantle them both side by side and see if anything is missing, back to front etc

I take numerous pics and vids whenever dismantling complex auto stuff, and its saved my butt more than once

Try backing out the Indicator Light Switch and the Detent Ball

there's any number of ways to miss something when re-assembling so without pulling the case out and opening it up to inspect itd be hard to stab at what could've gone wrong there.

As far as troubleshooting while the tcase is installed - Are you trying to shift it with the shift lever from inside the jeep OR did you remove the linkage from the shift arm attached to the case and attempt to shift it there?

Shifting shouldn't be difficult enough to require a hammer to make it move - you're only asking for more problems with that approach.

I would guess if after removing the linkage and still no go on the shift manually from the shift arm then it should come back out for internal inspection

Double check the shift fork, it's easy to install wrong and is a common issue.

Giving an update:
I took the case out and apart and was surprised to find that everything was where it was supposed to be. None of the shift forks were installed wrong and removing the light switch and detent ball didn’t solve anything. Initially, I thought I forgot the spring that sits on the shift fork rod, but that was accounted for. I referenced videos on Youtube and my repair manual and from what I could tell I reassembled correctly.

What I did find out was this: the little nub on the back of the mode fork was sitting on the sector with too much pressure. Everything I tried to get it to move didn’t help much so I just came up with temporary solution.

I took the forks out, put the sector into 2wd, and reassembled everything around that. The good news is that my Cherokee isn’t stuck in neutral, the bad news is now it’s stuck in 2wd.

Honestly, I’ll just take that at this point. I’m at best a novice when it comes to stuff like this and I’m nowhere near knowledgeable enough to completely solve it. Since it’s at least drivable now, I‘m gonna take it to a shop and see if they can sort it out. The way I see it, it’s probably better to take it to more experienced people instead of me just fiddling around with it in my driveway.

Anyways, thanks for the help guys! See you in the woods!