NP242 pops out of 4low into neutral.

Howdy! I've done quite a bit of searching and haven't run into much information on my problem. I've got a 91 cherokee 4.0 aw4 Np242. About two months ago I replaced a stretched transfer case chain and put a lock right locker in the front.

It worked great for a few wheeling trips, but now my np242 won't stay in 4 low. Whenever I decelerate or come up to a rock, it pops the t case into neutral. I've already adjusted the linkage all over the place, but it is definitely something inside the transfer case. The t-case works great in every other mode/range, but it just won't stay in 4 low any more.

I've read a little about worn shift fork bushings, but i'm hoping someone can shed some light on the subject for me before I rip into the case again. THanks!

The little plastic pads that go on the shift forks probably need replaced. Mine had the same problem and I had a couple pads that were broken when I opened it up. I think the replacement pads were like $12 on eBay.

Ditto on my 85 xj. Make sure you check the slide gear too. Mine

actually wore and a taper developed and would throw it into neutral even with new fork pads. I had to replace the gear.

Did you look at the linkage to see if it slipped? Mine did that. And it's free to look.

Also, a bad transmission or motor mount can cause this. When you get loaded up on the rocks, the torque of low range will twist your entire drivetrain - and pull on the t-case linkage.

zachandandy said:

The little plastic pads that go on the shift forks probably need replaced. Mine had the same problem and I had a couple pads that were broken when I opened it up. I think the replacement pads were like $12 on eBay.

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This is exactly what was causing the problem I had with a NP242 slipping out of low into neutral. The little plastic tabs were broken and the shift fork was resting directly against the sliding gear.

Look at the mounts. Replace as necessary.

Then do this:

https://www.youtube.com/watch?v=BHp2hdvZ4oY