1995 NP231 Tcase Chain Rattle and Slip in 4WD Help

Hi
I hope someone with experience in tcase repair can help. I have a 1995 XJ 4.0 Country and it was driven for 5 hours on dry pavement in 4W high. The chain rattles constantly and loudly and when I put it in 4WH it seems like it "slips" i.e. just doesn't engage. I've checked the linkage adjustment and it's good.

My question is this: based on your experience what are the odds that it is just the chain that's shot as opposed to the chain and drive gears.

All thoughts greatly appreciated.

Thanks
Bruce

 

i have nothing to contribute, because i don't know one thing about tcase repair. but i do have a question.
something you probably should've asked the driver of the vehicle for those 5 hours.

Why was it driven in 4 high, for 5 hours... on dry pavement?

 

NEVER EVER use 4 high on dry pavement with np231,,,, that is your problem right there

 

Only way to know for sure is to open it up and inspect it. How many miles on it?

You may be able to salvage this transfer with a chain swap, cost is about $125. Or you could try a replacement transfer.

 

Why 5 hours on dry pavement? I asked my son the same question. No particularly good answer either.

My main goal at this point is to fix it for the lowest possible cost. The drive chain is definitely stretched to the max. I'm hoping that someone with experience rebuilding these can give me an opinion on whether they think the drive gears got worn out too.

Thanks
Bruce

 

If it's skipping teeth your taking on damage, a stretched chain will also eat at the aluminum case on the bottom as it runs along it.. and eventually eat a hole in it. Like i said, the only way to determine how much damage has been done is to open it up.

Where are you located?

 

I'm in CT

 

Pull the case out--If you can get under car its pretty easy--Buy a chain and front and rear seals and a cople of tubes of silicone gasket maker . you need an impact gun usually for the front driveshaft yoke nut. Split the cases and change the chain. Plan on spending a day your fordt time. Iy os pretty easy to do.
Steve

 

there is nothing to the NP231...I rebuilt mine new seals and chain, and inspection when I did my tranny swap. took about 90 minutes, and a bit of patience putting the 2 halfs back together.

 

it could be the chain streached and worn out...but youll have to take it apart...i just repaired my 231 and it wasnt hard at all...i got another case with everything inside it in pretty good shape, from a junkyard, a new seal and bushing for the rear housing...it was about 95 - 100 dollars

 

I pulled the front drive shaft and can clearly hear the chain hitting the case when I spin the yoke so the chains definitely shot and I hope it didn't take out one or both of the drive gears. I'm going to split the case on vehicle and hope that I can get away with just replacing the chain (and rear seal).
Thanks
Bruce

 

I replaced this tc with a newer one. When I took it apart I found that the chain was stretched beyond belief. The drive gears look good so I'll probably put a new chain in and sell it. The take away for me is I should have pulled the thing out and opened it up! Would have saved myself a loot of time and money! Thanks for all the help
Bruce

 

Freshen up your original.. $200 for the bearing/seal kit and a chain. Then swap it back in and sell the one you recently purchased.