the gear cut style changed but the splines and all are still sane

 

 

OP: Something I just found on Novak.

Again, you probably have an early version input shaft which has a smaller input bearing. (you should disassemble your TC again to check)

P231 Versions

NP231's are consistent from 1988-1993. Beginning in the 1994 model year, New Venture changed the front input bearing from a wide version to a narrow version. By 1995, the change-over was complete, but individuals with 1994 model year transfer cases can't always be certain of which bearing their transfer case may actually have, unless they pull the front bearing retainer or even fully disassemble the NP231 and check this input gear bearing.

• The early NP231 uses a BD50-8 bearing, measuring 24mm wide
• The later NP231 uses a 6010-N bearing, measuring 16mm wide

The earlier style input gear, left, has a wide bearing journal. The later style input gear, right, has a narrow bearing journal.

 

As I keep saying, it is not the input shaft as it is the original one that came off the jeep.

Nothing is new except the front case half. The oil seal on the trans is also the same, which it appears to be stuck on but it is hard to tell as I'm doing this whole process on a creeper in my driveway.

Tomorrow morning I'm going to pull the oil seal on the trans and see if that is whats stopping it. If it still doesn't slide on it seems ill have to take to t case apart and rebuild again.

 

Did you use same year case maybe casting different to fit different gear ?