NP231 Education for me.

[dkroll]

Hello Fellow Jeepers,

 I will start off by my specs to help, then my issues;

1988 Shortbed 4x4. 4.0L AX15 Rolling frame with no driveshafts, brake lines, ANYTHING! due to the stage I'm at on this. Rusty's 8 inch long arm on G2 Dana 44 front axle w/elect lock. Ford 8.8 rear SOA rear with disc brakes (just sitting there, not set in stone). Installed lift (long arm, replaced floorboard) and now wanting to get the rest of the "underneath" installed and dialed-in. It is SLOW work due to financial and time restrictions, so I have time to play with this hobby- It is driving me crazy for I only wish this project to move under it's own power by the end of 2015. Which leads me to my current status in this project. My NP231 Transfer Case.

 I have my engine ready and mounted with a chain holding up the rear of it, I can't dial-in my rear drive shaft until I conquer a few obstacles facing me right now. I have my transmission laying around (on the ground), and choose to disassemble my transfer case for a SYE, it has been apart for many many months on my bench due to (what I noticed, was a worn out Shift mode Fork), Found one and ready to install it, but here is my current issue;

 Happy with my new shift mode fork that I received the other day, but as I am looking at videos and wondering what the root cause of this failure, I notice no videos mention pieces I see in my Haynes book, page 7C-3 , part number(s) 52. As my fork is put in, I noticed the upper wear of the old fork was worn out 1/8 inch from the "top"(on bench), and of corse, the plastic tabs were toast!  By the looks of the videos I have been seeing, no one mentions these, and by the exploded view in my Haynes, these look like an inserted-type bushing instead of just being a flat washer-type set-up. My range fork doesn't look as though it is made to have bushings "inserted" into it's self, So I question if this is an option in some of the NP231's or what I am not understanding. If I need these, it seems that they would be 1/16 inch each. I am lost!

 After this issue, I need to find a transmission mount which will enable me to get closer to having everything mounted from my Rusty's crossmember on forward. Once there, I can get my driveshaft built.

 I need help from anybody who has done anything like this- My ax15 is from a 94-95 YJ, and the mount on it seems to not be the right one, I need to know what would work to put this all together. Photos would be nice!

Help!

[husky410ohio]

When I took my NP231 apart and replaced the chain and added the SYE someone in the forum posted the 86 factory manual section for the NP231 that was a big help for.  I saved it as a pdf and could email it to you.  It is 28 pages and 6.8MB file size.  The stupid Haynes or chilton manual that came with truck when I got it said do not attempt to take it apart because it is too difficult to do.