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Stock XJ Cherokee Tech. All XJ Non-modified/stock questions go hereXJ (84-01)
All OEM related XJ specific tech. Examples, no start, general maintenance or anything that's stock.
****UPDATE 1***
So I unscrewed the vacuum switch from the NP242 that I put on the NP231, and replugged the vacuum switch from the NP231. Now it will go in 4Hi and 4Lo but not 2wd. I think whatever is under the plug might have gotten bent from the Np242 vacuum switch being longer and screwing deeper into the case. Anyone know what might be below that vacuum switch?
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****UPDATE 2****
The switches are different for my 91 NP242 vs the Np231 I sourced from a 98 TJ. The NP231 has a 4 port vacuum switch and my NP242 has no vacuum switch, but it does have a plug that indicates to the dash what mode I'm in (i.e. part time 4x4). The issue seems to be that the NP231 needs vacuum to disengage 4wd.
I can cycle the shifter arm through the 2wd/4hi/N/4lo positions but the transfer case wont disengage from 4wd to 2wd even when the shifter arm is in the 2wd position (so it stays in 4hi even in the 2wd position).
I just installed an NP231 in my XJ and before I installed the transfer case, I could manually change the gears with my hand on the transfer case.
It looks like I need an NP231 vacuum switch harness, but I have no idea what to hook it up to on my XJ as it did not need this harness with the NP242. Simply screwing in the NP242 plug does not work.
Below is the NP231 plug
Here is my NP242 harness.
Thanks for the help!
Last edited by jdjordan; 11-12-2015 at 08:08 PM.
Reason: Update 2
****UPDATE***
So I unscrewed the vacuum switch from the NP242 that I put on the NP231, and replugged the vacuum switch from the NP231. Now it will go in 4Hi and 4Lo but not 2wd. I think whatever is under the plug might have gotten bent from the Np242 vacuum switch being longer and screwing deeper into the case. Anyone know what might be below that vacuum switch?
________
I just installed an NP231 in my XJ and before I installed the transfer case, I could manually change the gears with my hand on the transfer case. Now that I have installed the transfer case, the shift arm on the side of the case that changes the gears wont budge. Wont budge as in I can hit it with a hammer and it wont move a millimeter.
The only parts I did change on the NP231 is swapping the plugs from the NP242 to the NP231 as my Jeep is a 90 and the NP231 was from a 98. Would plug sensors effect the shift arm?
Thanks for the help!
Try removing that switch and see if it shifts okay.
Sounds like you need a factory service manual so you can see what goes on inside the TC.
Try removing that switch and see if it shifts okay.
Sounds like you need a factory service manual so you can see what goes on inside the TC.
Thanks for the info. If you have the chance, can you take a look at the update in my 1st post and see if you have any ideas? I have the factory service manual but unfortunately it doesnt have guidelines for an NP242 to NP231 swap
The mode select switch rides on what is called a "Shift Sector". Its a cam-like device with lobes that the mode switch plunger rides on. If the wrong switch for the TC is used it may jamb up the movement of the Shift Sector. That's why I suggested removing the mode select switch and see if the shifting interference is still there.
If you are still confused I can post up a pic of the shift sector.
The mode select switch rides on what is called a "Shift Sector". Its a cam-like device with lobes that the mode switch plunger rides on. If the wrong switch for the TC is used it may jamb up the movement of the Shift Sector. That's why I suggested removing the mode select switch and see if the shifting interference is still there.
If you are still confused I can post up a pic of the shift sector.
Thanks CCken
I know what the switch selector is, as that is what I am manually moving to switch the TC from 4lo/N/4hi/2wd. It freely moves with or without the mode switch plunger screwed in. Even when I take it out and stick my finger in the hole and switch gears, I can feel the cam moving in there. However, my issue now is that the NP231 relies on vacuum to engage and disengage 4wd and the NP242 did not need this. So my XJ doesnt have the vacuum lines available to plug into the Vacuum Switch. You can see the vacuum switch below. I dont have the plug that should go into this to engage and disengage 4wd. The harness/plug attached to my XJ and vacuum switch for my NP242 is below
Now you'll need a 231 connector for the two-pin switch - correct...
No, my XJ has the 2 pin connector in the harness that was used in the NP242. I think the issue was that I got the TC from a Wrangler and it uses a different plug and harness
No, my XJ has the 2 pin connector in the harness that was used in the NP242. I think the issue was that I got the TC from a Wrangler and it uses a different plug and harness
not yet, i just have the bezel for now. gotta make a run to pick n pull to grab one. however I have been told that it isnt needed, but highly recommended
11-11-2015, 11:59 PM
Transfer Case Stuck In Neutral
