Looks like your missing the clip to secure the cable to the mounting point.
Figure 6 - clip is depicted just to the right of the NV242.

 

Thanks ! but, the 'clip' you mention is the metal one that goes farther back on the cable that holds it to the transfer case and not the one at the tip/end of the cable as shown in my picture. I am finding that there is a plastic 'bushing' that goes in there. Apparently they make a few different ones for this same model so I need to make sure I get the correct one. My VIN at the dealer may be the best bet as believe it or not, they sell these bushings fairly cheap and would know which one I need, although I am told these can be bought at parts stores locally, just got to get the right one ! If someone here knows how to figure out the 'right one' for me I`d appreciate it ! lol Thanks again !

 

OK, after much research (by me and Kolak) it seems there is a plastic bushing like thing that holds the end of the transfer gearshift cable to the little nub on the linkage on the NP242 transfer case. It is the green thing in the picture as seen here: https://www.quadratec.com/products/...ts/52218_0014.htm?gclid=EAIaIQobChMIioSXu_Hd3wIVCqxpCh0bVg__EAQYBCABEgJJNPD_BwE

However, if you read the fine print you`ll see that part supposedly stops with 98 models:

• Fits 97-06 Wrangler TJ with NP231 or NV241OR Transfer Case
• Fits 87-95 Wrangler YJ with NP231 Transfer Case
• Fits 87-01 Cherokee XJ with NP231 or NP242 Transfer Case
• Fits 87-92 Comanche MJ with NP242 Transfer Case
• Fits 93-98 Grand Cherokee ZJ with NP242 or NP249 Transfer Case

Further digging we learn for my 99 WJ that the only way to get that bushing is to order the entire cable = $100 +/- (see attached pic) !!!!

If Jeep stopped selling the $1.99 bushing for my `99 GC so they could make more money selling the entire cables well shame on them ! But, if the bushing is actually different (which I seriously doubt because we are dealing with the same NP242 Transfer Case) then it should be available to buy which is isn`t so,,,,,,, I am almost willing to bet that the same bushing (green one pictured) for the 98 ZJ, WILL fit my 99 WJ !!

I have one on the way so as soon as I get to it I`ll post the results of this experiment ! (anyone care to make any predictions or bets on how this will turn out ? lol)

 

I had to replace the same bushing. Dorman sells a pack of them for around $3.

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Do you know the dorman part number?

 

What year is yours ?

 

I have an 03, 4.0/Selec-trac

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Yes a part number would be great as @Kolak nor I have been able to find the bushing sold separately.

UPDATE ON THE LITTLE GREEN BUSHING KOLAK SENT ME TO TRY ON MINE !!!

It did not fit Pics attached. Does not fit the cable nor the linkage ,,, fairly hard plastic so I could not force it on either,, do not feel like drilling it out, so I just put an e-clip on it for now which seems to work (although it could use a washer behind it) but as you can see the narrow area at end of linkage is not actually a slot for an e-clip I dont think,, this does require the white bushing very similar to this green one that is seen in my earlier pic of the cable assy but, so far no one can find THAT bushing sold separately. if anyone knows the part # for the right bushing I would greatly appreciate it !

 

Try bushingfix.com. Just had to do this on my 04 with 242 after swapping t case. $25 which is a lot for what it is but it worked and better than buying a whole new cable. Did have to dremel the edge down just a bit to get it to fit just FYI.

 

Thanks for that information ! This thing has been working without ANY thing holding it on as the way the cable mounts it cant really move so it doesnt come off, I just seen it when I was under there and knew it was missing something ! Gonna see how long my e clip lasts before spending $25 for something that tiny LOL I could probly dremel the one I have and make it fit actually !!

 

Yeah really all it's doing is taking the slack out. I bet you could make that one you have work too if it really bothers you.

 

Yep, mine fell off 2 weeks ago while i was replacing my crank position sensor.I couldnt find anything except the $25 plastic thing. I used a 1/4×3/8 bronze bushing,some thin stainless washers and a 1/4 lock collar.It is probably better than new now.

 

I had the same thing happen a few months back and also searched fruitlessly for the right replacement part. I ended up buying the Dorman 14041 miscellaneous bushing kit and the Dorman 13441 push nut kit.

The bushing ID didn't quite match so I drilled it out with a handheld drill. Then I removed the OD taper to create a straight shaft by lathing it, with the bushing still on the drill bit and a chisel in a vise.

I tried an e-clip but didn't feel like it was secure. The push nut was better but I split a few before finessing it over the shaft and then using a punch to flatten down the tabs.

Photos:

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fhunziker

Excellent repair method and thanks for posting the detailed pics ! I am sure the green bushing I have now will work for that exact same fix once I drill it out some and I will surely use the metal clip like you did as well to make sure it don't come off. Right now I am fighting water leaks and 4 wet floorboards but, hoping to have time to get back to this needed repair soon !

 

Pretty good fix, but keep in mind that push nut is going to be a bear to remove if you ever have to drop the transfer case. Easiest way I see to get it off is a Dremel tool!

 

Had this come up on my WJ this week. For folks in the future that this happens to and are looking for a fix.

mine is a 247 transfer case. The bushingfix.com WJ1Kit red bushing worked great. Wound up getting it on Amazon, but that was to get it a little faster.
After several failed installation attempts, here are a couple suggestions.
Find yourself a small c-clamp. I used the big one I use for brakes, was cumbersome. Had a lever one that was good size, but did not offer enough pressure. Use double sided tape or something to attach the bushing to one side of the C-Clamp and on the other side attach a small socket. This keeps you from needing more hands than most people have, holding everything in place. The socket allows the bushing to be pressed on, and go inside the socket on the other side. If it does not seat all the way, use a little screwdriver to encourage it the rest of the way. Did not need much encouragement once it was mostly on.
Thanks for the pointer towards bushingfix.
I opted not to use zip ties, although a few properly placed would likely have functioned well.
Sorry no fixed pic, just imagine a small red bushing there. Felt very secure and seems to be doing a great job.

 

Here's the bushing kit I used.

https://amzn.to/41v6WIO

It ended up the smallest bushing in the set, and it was difficult to install. (Really tight fit) I ended up using a "C" clamp as a press to press it on.