I have a transfer case out of a 96 Grand Cherokee with the 42RE transmission. It looks identical to the transfer case on my 96 Cherokee with the AW4 transmission. When I try to put it on the transmisison it stops with about 1/2" remaining. The output shaft spline count on both transmissions is identical, however, the spline on the 42RE is only splined part of the way on the shaft (see photo). The AW4 spline goes all the way to the end of the shaft. That appears to be what is keeping the transfer case from going all of the way in. Is there any way that this transfer case will work or am I just kicking a dead horse?

 

You can change the transfercase input shaft to the proper spline configuration.

 

How difficult is this? Has anyone got instructions or is there a thread posted somewhere?

Thanks for your help.