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Old 04-25-2016, 08:09 AM
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waterlogd2005 waterlogd2005 is offline
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Default SYE for the XJ

So I finally broke down and put the SYE in the 88 XJ. Well more like if I didn't put it in Ghosty was going to throw the rear drive shaft. Been hearing a squeak and vibrations greased all of the U joints it finally ate the cap on the upper U joint with the slip yoke. Junkyard and I pulled the transfer case and installed the SYE. Had to beat out the bearings in the gears due to the new shaft not needing those needle bearings. Got it all back together. Can't shift to N or 4LO. 2HI and 4HI are all good. It doesn't seem to be anything major. Junkyard says we need to pull it apart and make sure the gears are aligned. Not doubting him I just wanted to see if anyone else had this issue after installing a SYE in an NP231.
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Old 04-25-2016, 08:15 PM
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Default Re: SYE for the XJ

Quote:
Originally Posted by waterlogd2005 View Post
So I finally broke down and put the SYE in the 88 XJ. Well more like if I didn't put it in Ghosty was going to throw the rear drive shaft. Been hearing a squeak and vibrations greased all of the U joints it finally ate the cap on the upper U joint with the slip yoke. Junkyard and I pulled the transfer case and installed the SYE. Had to beat out the bearings in the gears due to the new shaft not needing those needle bearings. Got it all back together. Can't shift to N or 4LO. 2HI and 4HI are all good. It doesn't seem to be anything major. Junkyard says we need to pull it apart and make sure the gears are aligned. Not doubting him I just wanted to see if anyone else had this issue after installing a SYE in an NP231.
Some ting wong
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Old 04-26-2016, 09:28 AM
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Default Re: SYE for the XJ

Looks like next week the transfer case is coming back out. We believe the gears turned when we tapped out the bearings. Early 231s had bearings that New Process later decided weren't needed. We need to pull it down and make sure the gears slide on the main shaft with out binding and make sure they are aligned with the front shaft properly. At the moment I just can't go into 4lo. Who needs 4LO? Why do something once when you can do it twice? The first time was just practice.
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88 Cherokee XJ with 6.5 inch spring lift running 33s. The Grey Ghost.
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Old 04-26-2016, 10:29 AM
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Default Re: SYE for the XJ

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Originally Posted by waterlogd2005 View Post
Looks like next week the transfer case is coming back out. We believe the gears turned when we tapped out the bearings. Early 231s had bearings that New Process later decided weren't needed. We need to pull it down and make sure the gears slide on the main shaft with out binding and make sure they are aligned with the front shaft properly. At the moment I just can't go into 4lo. Who needs 4LO? Why do something once when you can do it twice? The first time was just practice.
you still plan to go to Icebreakers without 4LOW?

I assume you guys pulled the back half of the case off and the shifter mechanism isn't messed up somehow? something simple maybe?
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Old 04-26-2016, 11:38 AM
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Default Re: SYE for the XJ

I am not going to make Ice Breakers I am in a wedding here in the county. Junkyard and his wife are going. I will have it fixed before trail cleanup day.
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88 Cherokee XJ with 6.5 inch spring lift running 33s. The Grey Ghost.
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Old 04-29-2016, 10:44 PM
ehall ehall is offline
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Default Re: SYE for the XJ

Make sure the transmission is in neutral and driveline is unloaded. 4lo and neutral are on the front planetary which gets bound up by the input shaft really easily. It's even in the owners manual.
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Old 05-02-2016, 02:14 PM
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Default Re: SYE for the XJ

I usually put trans in Neutral and let foot off brake then press brake again before shifting from 4HI through N to 4LO with Jeep stopped. Doesn't seem to be doing the trick this time. I have driven it around it isn't making any noises and 4HI works fine. I even tried shifting to N and 4LO with tranny in Neutral and Jeep slightly rolling. Just won't slide past 4HI. Thanks for the advice. Transfer case is going to have to come back out. Something isn't lined up right on the gears. Wednesday evening we'll pull it and see what is going on.
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Old 05-06-2016, 11:35 AM
Lax22 Lax22 is offline
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Default Re: SYE for the XJ

Did you trim the shift fork shaft before reassembly? I had to do it ob my YJ when i installed an SYE. Its outlined in the directions as well...

NOTE: On some NP231 transfer cases,the shift rail must be shortened. This shift rail protrudes out of the transfer case and goes into the tailhousing. The new tailhousing has a pocket depth of 1.125".

Shift your transfer case into 4WD so the shift rod is protruding the furthest out of the transfer case. If this shifter rod protrudes more than 1" out of the back side of the transfer case, then the shift rail must be shortened. Ideally the shift rod should protrude exactly 1".

Transfer cases that will normally require this rail to be shortened measure 1.5"

Using a hack saw or cutoff wheel (and safety glasses), trim the shift rail shaft so that it protrudes only 1"

This kit is designed for both the Cherokees and Wranglers. The Cherokees use a vacuum actuator on the New Process tailhousing; our casting has this provision. On Wranglers, this threaded hole must be plugged. We have provided a plug and washer for this purpose. We also recommend that you use a bit of silicone to properly seal the plug.

Just something to check while you have it apart, as a side note I had a 99 TJ that did exactly what you are describing. IT wouldn't shift into 4 LOW while idling but if i shut off the motor it would shift no problem. I never dug into it so just an observation. Hope you get it all figured out.

Last edited by Lax22; 05-06-2016 at 11:43 AM.
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Old 05-06-2016, 01:38 PM
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Default Re: SYE for the XJ

We got it fixed. I have 4LO again. When we separated the gears to tap out the bearings one of the gears got turned 1 tooth and would not let the shift collar slide past 4HI. We took them out realigned everything and slid the collar. It wouldn't slide at first but we moved the collar over 1 tooth and it all slides now. Ghosty is back together and no more drive line vibrations. A SYE also resolves issues with bad U joints (when you replace the rear drive shaft).
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88 Cherokee XJ with 6.5 inch spring lift running 33s. The Grey Ghost.
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Old 05-06-2016, 04:53 PM
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Default Re: SYE for the XJ

Quote:
Originally Posted by waterlogd2005 View Post
We got it fixed. I have 4LO again. When we separated the gears to tap out the bearings one of the gears got turned 1 tooth and would not let the shift collar slide past 4HI. We took them out realigned everything and slid the collar. It wouldn't slide at first but we moved the collar over 1 tooth and it all slides now. Ghosty is back together and no more drive line vibrations. A SYE also resolves issues with bad U joints (when you replace the rear drive shaft).
Awesome, What do you have left to get it ready to go wheeling the 14th?
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