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post #11 of Old 07-15-2012, 06:30 AM
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Join Date: Jan 2010
Location: Houston, Texas
Posts: 165

Originally Posted by BADGER View Post
How to fix transfer case linkage

Everyone has their own way, here’s how I did mine. No pictures – believe me, it will be easy to follow along.

1) First, drive home from the place where you had to be towed to on Chrysler’s dime when the thing broke, since your Poly Performance t-case skid made access impossible.

2) Go to the dealership and buy some of the offending bushings, just in case you need them. (you won’t; you’re developing a better solution). Marvel at the 35-cent butter-soft, heat-and-grease susceptible plastic component that disabled your vehicle.

3) Go to hardware store – acquire an assortment of steel sleeves, bushings, tubing, washers, and e-clips to craft your solution.

4) Pull Poly t-case skid – you will need arms the length of cro-magnon man to reach a few of the nuts underneath. Remove it and examine the shredded remains of previous bushing that nestled there. Set aside.

5) Realize that you can’t remove the shift pawl from the transfer case, because you’ve got a Rubicon – instead of the 10mm nut that the other models have, you have a little allen or torx head on there. Don’t bother getting your wrenches – it’s so close to the front driveshaft yoke there is no way to get to it off without pulling the drive shaft and yoke. Abandon idea of removing pawl. Understand you therefore can’t use anything you bought at the hardware store.

6) Install new butter-soft, heat-and-grease susceptible failure prone bushing into cable end. Cut bushing end flush with cable eye and slide on shaft. Take a washer and e-clip and get them into position.

7) Call Whiskey-Tango-Foxtrot as the washer and e-clip repeatedly bounce off your safety glasses and roll into oblivion every time you try to get pliers into the tiny, unreachable, convoluted spacers between the exhaust, driveshaft yoke, and cables. Abandon the e-clip idea.

8) Get into other car and drive back to hardware store. Buy some hitch pins. Come back and clip hitch pin into recess on end of shaft.

9) Done. Now have fun doing the console side.

10) Realize hours have gone by. Drink beer. Revel in your new deep, complete understanding of exactly why Chrysler quality is still regarded as the poorest in the industry and why we are all funding their bailout with every paycheck.

That’s it! You’ve done good. Now go break it again.

I drilled out the nipple on the lever and used a bolt / spacer etc about 3 years ago. Never have broke the console side of that connection. But this next week when I put in my new tuffy console I will go ahead and take care of that end as well.
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