Recently rebuilt my transfer case and I got it back in the Jeep however I can't seem to get the shift linkage in the correct position. I can get the Tcase in 4 lo with a wrench and the metal plate with that rectangle in it, I can get that on but then it's in the wrong position and the Tcase will be in 4lo while the lever says 2hi. I sprayed lube on that rod with the jam nut but can't seem to get it to move. I'll try that next but do you all have any tips? Inside I didn't even touch that part, just pulled the bearings and then the forks and sleeves. I figured it'd go back easily since I didn't change anything but apparently I was wrong

 

That can be a pain in the *** to adjust. I recently went through it. I had to have a 2nd person hold the lever in place and it took some not so gentle persuasion to get the clamp thing to slide on the rod correctly.

 

One of the rods has a slider and set screw. Take that loose and put the case in 2WD and shifter all the way down. Retighten the screw/bolt and then check positions for all gears

 

Thanks for the info. It's soaking now. I'll try to bust it loose tomorrow since it's pouring cats and dogs now. Also another thing I've noticed is that when I try to put that plate onto the piece coming out of the transfer case it'll fit on all gears except 2 hi, 2 hi is moving that piece till it clicks all the way to the rear but the metal plate bottoms out on the case. I'll see if I can get it on in another position and try to get it working but I'm almost betting it won't go into 2hi fully. We'll see, thanks again

 

(with an AW4 and NP242)

I unbolted all the shifter parts underneath and disconnected the mechanism from the TC shifter shaft

You should be able to move the shifter shaft fairly easily with multigrips into each position

(You should actually just be able to undo one bolt and work it free from the actuator to check this

As mentioned already, there is an adjuster setscrew/nuts on one of the rods

The reason I unbolted everything is I didnt want to stress the hard plastic bushes

Unfortunately there is a bit too much slop in the design, especially if there is wear in the bushes imo

(It does require the trans and TX case to be jacked up & down, to take out all the parts, and I was swapping out the trans anyway)

 

You sure you have the lever on the xfer case end on correctly and everything put back together on the linkage correctly? Not upside down and pointing the wrong direction? On my 89, the 2-H position is pointing down and forward about 8-oclock.