Transfer case linkage coming loose

bighause · **Posted:** Sat Dec 26, 2009 4:33 pm

I noticed my 4wd shifter has more play than it used to so I looked into it and the end of the cable that attaches to the shift arm on the xfer case seems to be the problem. It has a metal loop with a rubber bushing that pushes onto a stem on the shift arm. The bushing is mostly gone and the loop is very loose on the stem.

Has anyone else had this problem? Were did you find the bushing? It looks like a pretty simple fix if I can find a replacement part for it.

TexasRock · **Posted:** Sun Dec 27, 2009 10:05 am

Same thing happened to mine... I just bought a cotter pin from HD and haven't had a problem since...

Nice looking KJ by the way... another Texas KJ! :SOMBRERO:

kjon · **Posted:** Sun Dec 27, 2009 11:36 pm

I've been having some issues with this as well. This last spring I was cruising country roads and found a spot that definitely required 4wd. I pulled up my 4wd lever and there was no tension on it, and it did not engage the 4wd. So, I crawled under my Jeep (one more reason to be lifted :lol:

) and found that the metal loop with rubber bushing (as described) had slipped off of the stem from the t-case shift arm (as described). I slipped it back on and went on my merry way with no 4wd problems for a while. Then it happened again a couple weeks later, so I pulled that bushing out and found that it was destroyed. I looked everywhere for a replacement, and finally resorted to the dealership (who charged me $30 for a piece of rubber the size of a thimble :roll:

). That worked for a while too, but just the other day I tried to engage 4wd again and it didn't work. I crawled under the jeep in the snow and slipped it back on, and I don't foresee being in two-wheel drive for a while, but I do need to get this fixed...

Where does the cotter pin go? It doesn't feel like there's enough room on the stem to fit a cotter pin. Can you post a picture?
Is there a bigger issue that is causing it to slip off? I've heard people talk about getting their linkage adjusted. What does that entail?

bighause · **Posted:** Tue Dec 29, 2009 10:18 pm

My cable has not actually come off yet, but the rubber bushing is completely gone now. I guess I will be heading to the dealer tomorrow to order a new one. Hopefully it will last another 7 years like the original part. It sure would be nice if there was enough room to get your hand up there to replace the bushing without removing the front drive shaft :evil:

TexasRock · **Posted:** Wed Dec 30, 2009 7:00 pm

Where you pushed it back on, there is a little "lip" on the end of that pin. I just pushed mine on, mind you with some force, past that little lip and added a cotter pin as a retaining pin. I also used some heavy wire and wired it in a "horseshoe"... been like that for a while now, and have used the 4x4 plenty since I did that.

I will see if I can get a pic of it...

Keith

kjon · **Posted:** Wed Dec 30, 2009 7:47 pm

Before you remove your front drive shaft... I can get my hand up there without removing anything, not even skids, and I definitely have man hands. It's easier to get to from the rear than it is from the front. I also have a manual transmission, so it might be somewhat different...

bighause · **Posted:** Wed Dec 30, 2009 8:59 pm

With the auto tranny, I can barely get my hand up there to wiggle the end of the cable and I don't think I would be able to replace the bushing. The transfer case skid eliminates any possibility of getting to it from the back. The drive shaft comes out in about 10 mins or so and will give me a lot more room to work.

Yet another reason to buy a manual tranny I guess...

TexasRock · **Posted:** Thu Dec 31, 2009 1:23 am

Trust me, I was under there for a while trying to get my hands at all the right angles... it wasn't easy.

Transfer case linkage coming loose

Who is online