Rolls in gear

[RCP Phx]

No, it would cause you to burn up/seize the case but not what your describing.

[Agreen]

For those of you saying it's something with the parking pawl, do this: Go put your transfer case in neutral. Start the jeep, put it in drive, then put it in park. You'll hear the noise he's talking about.

What you have here, JMO, is an issue inside the transfer case. On a wild guess, I'd say the shift forks weren't aligned properly and it's just staying in neutral. (Transfer case neutral, that is). You need to take the case back off and crack it open again. Diagnosis without the vehicle in front of you is difficult, but this is a no-brainer. The t-case must come back off, and you need to find out why it's staying in neutral.

[JMO1990renix]

Thank you Agreen! I am pulling the transfer case off today after work. I truly appreciate everyone’s help and will let you know what is going on as soon as I know. I truly appreciate the XJ Family willing to help me.

[JMO1990renix]

So guys may I start off with apologizing. I’m sorry for not simply checking my work prior to asking you all for help and occupying your time. I am eight months into recovering from being hit on the freeway while riding my motorcycle and working on my Jeep was me trying to get back into motion. I am realizing I am struggling with my memory. The issue was simply the shift for in the wrong location. I pulled the transfer case out today. I will tear it apart tomorrow and put it back together right this time. Hopefully... once again I am sorry and I truly appreciate everyone of you who took the time to chime in. Thank you.

[Agreen]

Very nice! I'm glad you found the issue. You can check the operation before reinstalling the transfer case too. Spin the input shaft and check the output shafts as you shift through the ranges. And as was mentioned before, you also need to check the shift linkage for the proper adjustment once it's all put back together.

[JMO1990renix]

Pulled it all apart and realized I installed the synchro sleeve backwards. Easy fix if anyone ever encounters these symptoms. Thank you all for your help.

[JMO1990renix]

Bad news. I flipped the synchro sleeve and installed the transfer case and still nothing.

[JMO1990renix]

Could it have anything to do with the original transfer case being vacuum and the new one not being vacuum? Is it possible that the computer is receiving the command from the vacuum?

[techno1154]

Originally Posted by JMO1990renix

Could it have anything to do with the original transfer case being vacuum and the new one not being vacuum? Is it possible that the computer is receiving the command from the vacuum?

Which transfer case do you have? Most XJ's have the NP-231 but over the years several TC's were used.

Personally, my only experience was to replace the out put shaft with a SYE shaft in the NP-231. According to the manual I have, that TC not complicated at all. Some others with AWD and/or vacuum operated could be a bit more finicky to repair, (I think).

You may be able to get more help if the group know exactly what you are working with.

[JMO1990renix]

Both are np231

[JMO1990renix]

Thank you Patrick

[JMO1990renix]

I came across a 1991 Cherokee that I pulled the transmission and transfer case out of. I put the sye in the 1991 transfer case and installed that in my 1990 Jeep Cherokee. The 1990 was vacuum and the 1991 was not.

[RCP Phx]

That sounds like your problem, the '90 is 21 spline and the '91 should be a 23 spline!
https://www.novak-adapt.com/knowledg...g-input-gears/

[RCP Phx]

That was kind of important info to leave out! At this point you could either swap over the SYE or look at swapping out the input gear but you will have to be aware of the gear cut and the length.

[JMO1990renix]

Thank you sir you are 100% correct. I went and measured the transmission and transfer case I have out. Thank you so much. The next question is can I simply just swap the input gear? Or do I just put the sye in the 1990 transfer case?