NP231 Transfer case problems (Kicking Myself)

I put a PORC SYE on my 1996. They did not give me a bolt to plug the hole where the shift rail comes in and out so I plugged it with another bolt wrapped in electrical tape. I noticed some clicking and clunking in 4wd and eventually some binding up and feeling funny in 4x4 that would go away when I put it into 2wd or when put into reverse. Apparently the plug came out and I have been running for some time with very little Dex III in the transfer case. I have replugged it and refilled it but now the internal condition of my transfer case is unknown. I think my chain may be stretched but don't know what other problems I may have caused. Any thoughts on a rebuild or other course of action? What should I do from here?

You really won't know what damage you've done until you open the TC.


Depending on what you find, you could try a rebuild kit http://www.jbconversions.com/pages/products/rebuild/index.html
or a new TC from the same place.

You could gamble on a JY take out or get a rebuilt unit.

More than likely, the bearings have been badly worn as well.