91 transfer case not wanting to go in our 95 auto transmission. Please Help. We are putting a 95 HO xj motor in our 91 xj but we are forced to use our 91 transfer case because the 95 transfer case is electrically controlled by the brain in the 95 xj, and our 91 xj has some weird brightly colored colored vacuum lines plug in that I think we have to use to be compatible with the power-train control module.
Can someone please tell us if they are interchangeable. The transfer case is really heavy and even though we have it strapped to a wooden cradle with a round cut out to fit the floor jack it is still awkward as all get out. the bolt pattern is the same and looks like the splines are the same but we could not get it to go in. Are they just hard to get started? I even tried turning the yoke a little while pushing. Please Help and thank you every one who always help us. 530-496-3413

 

The transfer cases are not electronicaly controlled, the 95 will have a plug on the top for the 4x4 light on the dash, and a speed sensor on the rear tailhousing. The vacuum lines on your 91 are for the front axle actuator. If it was me I would use the 95 transfer case, and permanently lock your CAD on the front axle.

 

the 95 will fit right in, you just may have to pull it, and try again. maybe a few times, but you will get it. i had to do the same thing on my last t-case rebuild. it was the original case, so i knew it fit, but got all frustrated as he'll, but all of a sudden, it just fit on perfectly. didn't think i did anything differently, but it worked. and i was just manhandling it, no jack. wasn't sure just how many times in a row that i can benchpress this thing on there before my arms just give out.

i have a transmission jack, but those things are pretty cumbersome, and you have to have all the tilts perfect, i just find it easier to manhandle it.

do as 444 said, and just permanently lock the CAD with whichever way you desire, there are a bunch of writeups here on the forum. i used a hose clamp around the shaft up against the slide collar. worked for a few years till i swapped diffs.