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Kicking a necrothread here, but I had to take a poke at the math. If he was getting 13MPG on an 18gal tank, that's 234 miles per tank. If he gets 30 extra miles, that's 264 miles per tank, or 14.7 MPG - basically a 12% saving. If he was getting 16MPG on an 18gal tank, an extra 30 miles would...

Well I did twice, but apparently not enough! Either that or I bolted it up with tension on the sleeve/shaft.

When I unbolted the output housing the shifter dropped into place. It is the sleeve piece (from the upper fork) not the shaft itself that is binding. I'll have to take a look at the alignment of the output housing. Unfortunately a can feel a tiny little bit of binding when I spin the now freed...

Oh your video was really helpful. The front and rear outputs on my TC are also in locked mode in neutral, but disconnected from input (wasn't sure if that was by design). The front output is disconnected in 2H. Back to the drawing board!!

Thanks. I did notice the shifter rail had to be pulled a little anti-clockwise (on the output housing rotation) to get everything buttoned up. And now that I think about that.... how can it possibly slide up and down if it is under side tension? Maybe I'll just take the output housing and...

Have you spun them by hand on a 242 on your bench?

Have not, planning to do that Saturday. I don't really want to crack the case again if this is normal behavior. But then I also don't want to have to install and remove it if this turns out to be an issue.

Everything is snug. The fork is able to select the locked (4H PT) and open (2H) modes.

I've just rebuilt my 242. I haven't put it back in the car yet, but I'm wondering if you should be able to turn the rear output and front output flanges at different rates (like an open axle) by hand in 4H Full time mode. All of the modes seem correct, but at least by hand, 4H FT feels just...

No one has answer the question of "where does the rest of the gray wire go from the ECU?" (the one that you splice into)

(edit) never mind