Do you guys have any tips on making a homemade transfer case linkage on a stock 1996 Jeep XJ 4x4 with an automatic?
The factory transfer case shifters can be fussy on XJs, and we can only assume you're tired of messing with the shifter on yours. You also didn't mention which transfer case you have, but most likely you have an NP231 or NP242. Rather than attempt to fabricate a homemade shifter, we would recommend going with a cable shifter from Novak Conversions (novak-adapt.com). The Novak cable shifter replaces the factory linkage system with a much simpler and more reliable cable-operated mechanism. The shifter bracket attaches entirely to the transfer case, eliminating any bind caused by the drivetrain moving around under the body. It also retains the factory shift lever on the center console. Best of all, the whole conversion is under $200.