Need emergency 231 sye help.

[matt0106]

I just recently installed a Rugged Ridge SYE on my 231. I followed the directions and put it all back together. Now it won't shift into 2wd nor will the Jeep move in 4hi or 4lo. It also makes a grinding-ish sounding noise when I shift my transmission from any gear into park. I'm confused as to why all this is happening. I just need help trying to figure out why all of this is going on. This is my daily driver and I'm tired of having someone else drive me around. Any help would be appreciated. Thanks in advance guys.

Info:
*4.0 I6 engine
*AW4 auto tranny
*NP231J transfer case
*Rugged Ridge SYE

P.S. I had to cut the shift fork rod down, but that shouldn't be the problem, it's not hitting the output housing

[Mudderoy]

I just recently installed a Rugged Ridge SYE on my 231. I followed the directions and put it all back together. Now it won't shift into 2wd nor will the Jeep move in 4hi or 4lo. It also makes a grinding-ish sounding noise when I shift my transmission from any gear into park. I'm confused as to why all this is happening. I just need help trying to figure out why all of this is going on. This is my daily driver and I'm tired of having someone else drive me around. Any help would be appreciated. Thanks in advance guys.

Info:
*4.0 I6 engine
*AW4 auto tranny
*NP231J transfer case
*Rugged Ridge SYE

P.S. I had to cut the shift fork rod down, but that shouldn't be the problem, it's not hitting the output housing

Did you remove the transfer case to install the SYE?

First thought is the linkage isn't adjusted correctly. Second thought is something ain't right inside. I'm hoping it isn't the second one.

[Brasscatz]

I sounds like your transfer case shifter is off. I'll see if I can find info on how to adjust your lever.

[Brasscatz]

http://www.naxja.org/forum/showthread.php?t=976227

Also, there's this:

NP231 & 242 Models

Remove the shifter lever bezel.

Place the range control lever in the 4 LOW position.

Insert a 1/8 in. (4mm) spacer between the forward edge of the shift gate and the lever.

Range control adjustment on the 231/242

Range control adjustment on the 231/242
Click to Enlarge

Hold the lever in this position with tape.

Raise and support the vehicle safely.

Loosen the trunnion lock bolt. The linkage rod should now slide freely in the trunnion.

Position the linkage rod so it is free in the range lever. Then tighten the locknut.

Lower the vehicle. Remove the spacer.

[matt0106]

Left it under there. My first thought is that I didn't put something on the inside back the way it's supposed to go in. People on some of the other forums say it's stuck in neutral.

[Mudderoy]

Left it under there. My first thought is that I didn't put something on the inside back the way it's supposed to go in. People on some of the other forums say it's stuck in neutral.

how does it feel when you shift the transfer case?

[matt0106]

Like it's sticking, it isn't smooth. It feels like it's scraping.

[Brasscatz]

weird...

Oh, I'm assuming that you refilled it when you reinstalled it?

[matt0106]

Yes, but it can't get any fluid circulated if nothing will move.

[4.3LXJ]

Matt, you are going to have to take that apart again. This time I suggest you pull the case and put it on a bench to do it. I think it is much easier that way. My first thought is that the shift fork is either not aligned into the slider correctly or the little pin is not in the cam. Also make sure your little spring that goes in the back is in. That is what takes it out of 4WD

[matt0106]

The spring is certainly in place. And how would I know if it isn't aligned right or if the pin isn't in position?

[4.3LXJ]

There are two shift yokes in the case. One is your low range shifter that has a pin that fits in a crooked slot in the cam that connects to the shift arm on the outside. The other remains on the outside of the cam and it operates 4WD/2WD. The spring pushes it back to 2WD

[matt0106]

Well since it was under the Jeep, everything just fell out when I pulled the main shaft. So, I stuck the low range shifter into the hole in the cam to get it in there. Could it be that it's stuck in the hole circled in red?
http://i493.photobucket.com/albums/rr299/matt0108/131_0905_10_zjeep_np231_transfer_case2wd_kit.jpg (http://s493.photobucket.com/user/matt0108/media/131_0905_10_zjeep_np231_transfer_case2wd_kit.jpg.h tml)

[4.3LXJ]

The low range shift fork is supposed to be there. I bet it is not now.

[Mudderoy]

I hope he lets us know what the fix was... :popcorn:

[BlueXJ]

That cam has to be out of place for him to have those symptoms.

[matt0106]

Alright guys, here is an update.
I had my mom shift the transfer case for me while I watched. Shift fork rod was not moving. Took off the rear half, and it didn't move. I had to guide it into the hole in the back half of the case. So, I think I'm going to have it in 4lo, put everything how it is supposed to go, then have someone shift to 2wd and guide everything into place. Then without sealing it put the rear half and output housing on, and put all the bolts back in, just to "mock it up," and have someone shift and cycle through 2wd-4lo a few times to check if its all working. If it all checks out, I will leave it in 2wd, then take it all back apart. Not touching any internals with it all working, I will then put gasket maker on everything and put it all back the correct and final way. Sound good?

[matt0106]

Also, here are some pics for ya'll to look at and let me know how everything checks out. I only removed the main shaft and didn't touch the two shift forks.

Here is the shift fork and hub thing:
http://i493.photobucket.com/albums/rr299/matt0108/Photo10.jpg (http://s493.photobucket.com/user/matt0108/media/Photo10.jpg.html)

Here is the shift fork pin and range selector pin with the cam:
http://i493.photobucket.com/albums/rr299/matt0108/Photo9.jpg (http://s493.photobucket.com/user/matt0108/media/Photo9.jpg.html)

Here is the main shaft with everything on it:
http://i493.photobucket.com/albums/rr299/matt0108/Photo7.jpg (http://s493.photobucket.com/user/matt0108/media/Photo7.jpg.html)
http://i493.photobucket.com/albums/rr299/matt0108/Photo4.jpg (http://s493.photobucket.com/user/matt0108/media/Photo4.jpg.html)

[Mudderoy]

I've only ever done a NP242...

http://youtu.be/jTOpd_pTb3g

Pay close attention to 7:09 min:sec

[4.3LXJ]

Looks like the shift forks are correct

[matt0106]

Bump. Still need help.

[4.3LXJ]

So have you taken it apart yet?

[matt0106]

Yeah, I'm pretty sure it has something to do with the shift fork rod. Gonna cut it down some more and smooth everything out on Thursday.

[Mudderoy]

Yeah, I'm pretty sure it has something to do with the shift fork rod. Gonna cut it down some more and smooth everything out on Thursday.

Did you watch that video? Did any of it pertain to what you're doing?

[matt0106]

Yeah, turns out I had everything right. Just didn't have the rod in the hole.

[matt0106]

So guys, long time no post. Well, good news. I got it figured out and fixed. Everything is working just fine, turns out the shift fork rod was the culprit. Also, assembly lube helped with, well, assembly.

[Mudderoy]

thanks for giving us the update.

[Dredwolf]

This is also makes the point when doing an SYE conversion, take the time to pull the case, take it under shelter, and do it on a bench.

If you don't have a bench, rig up a temp one, or build one that folds.

I have a garage, yes, but none of my "4 wheeled toys" will clear the door, but I learned one thing over the years.

Unless independently wealthy, You are going to spend more time than you EVER want working on some vehicle in the rain, snow, mud, dirt, dust, dark, heat while battling wind, rain, snow, dust, kids, your wife, dog(s), cat(s), sun, insects, neighbors, sleet, hail, locusts, fire ants, forum posts, etc.

It sucks. When you have time to take your time in shelter, DO IT! Your body, patience, and project will thank you.