I've done some light searching while here at work, but the threads returned are more catered towards people with multiple problems. I have a singular issue.

2001 XJ on 33's
I'm having the most difficult time trying to get my speedometer correctly set up. PO had a 33 tooth gear in the xfer case which reads 5mph less than actual speed. I know I need a 30 tooth gear, which I already have.
However, every time I try to install it and get everything sealed up, nothing registers on the speedometer on the dash. I've tried the current 30 tooth gear which seemingly does nothing, a 30 tooth long shaft gear that does nothing, and I always have to go back to the 33 tooth gear to get any speedometer activity. What am I missing or doing wrong? I never had these issues with my 87 Wrangler speedo when moving to 35's. Pulled old gear, put in new, and that worked fine. The cherokee refuses to play nice with anything I throw in the xfer case. The gear housing and clamp are properly seated and aligned with the notches. During the next break at work, I'm going to go out there and I'll find one of two things: Either the gear has been pulled from the housing socket and is sitting in the bottom of the case or it's still in the housing and its just not engaging, further stumping me and leaving me increasingly irritated. As far as I am aware, its indexing properly as well. Is there a trick to that I might be missing?

Someone make it make sense to me.

 

The speed sensor has several different positions it can be clocked to. The number range is imprinted on the sensor housing. Install clocked in the right position then lock it in with the metal lock tab. When installing, Jimmie the assembly a little bit to make sure the gears mesh properly.

 

I've tried everything I can think of. Several different speedo gears, all in varying sizes and lengths. Someone, for the love of God, point me towards a confirmed 30 tooth gear. The latest one that just got delivered this morning was small enough that I could tell as soon as I pulled it out of the package that it wasn't going to work. It was like 2/3 the size of the 33 tooth one in there now. It's obvious quadratec doesn't know what the **** they're sending me.

 

Or, you don't know WTF you're ordering. No offense.

Can you post more details on your rig? Transfer case, transmission, axle gear ratio, etc?

 

I went ahead and searched for a 30 tooth speed sensor gear based on what info you've already posted, assuming several things, I'm guessing AW4 with NP231 on 3.55 axles.

So, the replacement gear is going to be the long shaft, the short shafts are for wrangler, so ignore any charts with short shaft numbers. Every other chart I've seen, using the assumed specs and your tire size show no option for a 30 tooth gear. Meaning, they probably don't make one. The two closest options are a 28 tooth and a 32 tooth.

The jump to 33's really requires you to regear your axles in order to get back to "stock" values. Plug in the numbers with new gear ratios and you'll find the right speed sensor gear.

Until you regear, you'll have to compromise with a 28, a 32, or what you have, and you'll have to do math for mpg and such...and realize that until you do regear, it's going to stress your engine and transmission as it changes the shift points and rpms

 

Do you still have stock sensor...that gives correct length. On my old 92 i had to heat stock sensor to get steel driveshaft off.....then had to buy short shaft gear and heat the long steel shaft and then install while hot. I had to use a drillpress to keep the shaft aligned with gear