Official "How I permanently fixed my tcase linkage problem" thread - JKowners.com : Jeep Wrangler JK Forum
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post #1 of 33 Old 07-07-2010, 03:29 PM Thread Starter
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Official "How I permanently fixed my tcase linkage problem" thread

So it's happened to everybody.....including me last weekend a zillion miles from nowhere and out of cell phone range. Normally you just pop this thing back on and you're on your way. Well, not when you have a full Poly skid system. I wasn't getting anywhere near that thing....so Chrysler paid for a tow due to a 20-cent part failure.

What have you guys done for a more permanent, 'no worries' fix? I only want to have to drop that skid once. Yes, I searched, and came up with some good ideas. But it would be nice to have a thread with detailed ideas, parts and their sizes, how their holding up, etc etc. Let's hear 'em!

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post #2 of 33 Old 07-07-2010, 05:42 PM
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user error. just kidding

You can get a replacement bushing machined up out of metal but how it slips on but the physical loop on the cable itself is plastic too so I reckon it will fail again in the future even with a metal bushing.

Only real option would be to take the cable out and have its ends modified with some proper metal linkages, can't remember what they're called but they're the same sort of style as what most aftermarket swaybar droplink ends are.

Don't just do it at the transfer case end though - I helped a guy get his out of Low the other weekend, his was broken at the shifter inside the cabin!

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post #3 of 33 Old 07-07-2010, 06:00 PM
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I have a fix.
It will require a couple hours to do & will set you back close to $200.00 but it eliminates the problem all together. Also, it works in the factory location with a better cable & rod end connections.

Shoot me an Email.


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post #4 of 33 Old 07-07-2010, 07:12 PM
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I've crawled under my JK on the trail. Lucky I carry gloves in my tool bag. I used a tie wrap to hold the cable on until I could get home.

I was going to leave the plastic part inside the cable end and drill a hole in the lever and use a cotter pin. I'll probably still do that but I was just too lazy. So I put a new plastic piece on there. I always carry an extra one in the console.

I can't believe you couldn't use a stick or something to knock it back into 2wd to get home.


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post #5 of 33 Old 07-07-2010, 07:18 PM
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What .20 cent part are we talking about here? Sounds like something I should have on hand...
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post #6 of 33 Old 07-07-2010, 08:40 PM
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Quote:
Originally Posted by crusty1007 View Post
I have a fix.
It will require a couple hours to do & will set you back close to $200.00 but it eliminates the problem all together. Also, it works in the factory location with a better cable & rod end connections.

Shoot me an Email.

Sounds like a NEW PRODUCT release. I'm down for an upgrade, I'll be a guinny pig.

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post #7 of 33 Old 07-08-2010, 07:36 AM Thread Starter
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What .20 cent part are we talking about here? Sounds like something I should have on hand...
Shitty quality bushing that goes between the loop ends of the transfer case shift cable and the shift pawl on the transfer case (and lever inside the cabin). This piece of brilliant engineering is both susceptible to under-vehicle heat and slung grease, and actually contains the snap-in elements that hold it onto the pawl shafts. So when it breaks.....the cable comes off and the lever becomes as limp as Bob Dole. Usually you can crawl under there and zip-tie it while having the cat put 3rd-degree burns on your arm, with a belly pan I could not. If it breaks at the in-cabin end of the cable, good luck.

You best get you some to put into your boonie bag.

I'm going to track some down today and I'll post part numbers. Think I'm going to cut the bushing down and use a washer and e-clip to keep it from failing completely.

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post #8 of 33 Old 07-08-2010, 07:42 AM Thread Starter
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Originally Posted by CRDTom View Post
user error. just kidding
Funny you say that! I knew from the start that you have to baby the tcase shifts on these, and that strong-arming the thing could only bring you pain. So I shifted the thing as gently as the virgin snow since the day I brought it home. Guess how much it helped? I would estimate it's been in and out of 4-lo probably 50-ish times, always rolling slowly in neutral and letting it line up and engage without resistance. This is one shitty piece of engineering.

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post #9 of 33 Old 07-08-2010, 07:44 AM Thread Starter
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Quote:
Originally Posted by crusty1007 View Post
I have a fix.
It will require a couple hours to do & will set you back close to $200.00 but it eliminates the problem all together. Also, it works in the factory location with a better cable & rod end connections.

Shoot me an Email.

Sweet. Novak Adapters, by chance?

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post #10 of 33 Old 07-08-2010, 07:59 AM
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Quote:
Originally Posted by Skyjump136 View Post
What .20 cent part are we talking about here? Sounds like something I should have on hand...
Mopar Part #68064273 AA

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post #11 of 33 Old 07-08-2010, 08:35 AM
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I have shifted countless times in and out of 4wd with this setup. I did it shortly after getting my Jeep over a year ago. Looked at it the other day, looks just as snug when I installed it.

I pulled the cable down, ground off the plastic so it is flush with the cable end. Finagled a cotter pin over the nipple and snugged it down with pliers.

The load still rides on the plastic bushing, no slop in it because i kept the bushing, cotter pin just keeps it from flopping off. I wouldn't do anything else unless I broke the cable for some reason, which I think would be a little user error involved. Cost me about 5cents with how many cotter pins I own already.


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Last edited by Goodysgotacuda; 07-08-2010 at 08:37 AM.
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post #12 of 33 Old 07-08-2010, 09:16 AM
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Mopar Part #68064273 AA
Thanks for the part # Stub

Anyone have an online source to purchase? The local dealer is out of the way, and won't take orders over the phone- they require you come into the shop and pay in advance
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post #13 of 33 Old 07-08-2010, 09:25 AM
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Thanks for the part # Stub

Anyone have an online source to purchase? The local dealer is out of the way, and won't take orders over the phone- they require you come into the shop and pay in advance
The problem I found with ordering online is I can get the part for .24 cents, but get charged $8.50 for shipping.

In my case it will probably be best to just get them from the dealer or do a permanent fix myself.
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post #14 of 33 Old 07-08-2010, 09:50 AM Thread Starter
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In addition, I think replacing one crappy part with another is mildly retarded. I'm picking some up just so I can shave them down and leave the fastening part of the equation to something a hell of a lot more durable. I'd rather set it up once than crawl around in the dirt under a hot rig every few months just to replace the same failure-prone part.

I'm hitting Fastenal later, I'll report on correct clip and washer sizes and types, etc.

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post #15 of 33 Old 07-08-2010, 10:00 AM
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Quote:
Originally Posted by X-Defector View Post
In addition, I think replacing one crappy part with another is mildly retarded. I'm picking some up just so I can shave them down and leave the fastening part of the equation to something a hell of a lot more durable. I'd rather set it up once than crawl around in the dirt under a hot rig every few months just to replace the same failure-prone part.

I'm hitting Fastenal later, I'll report on correct clip and washer sizes and types, etc.
...looking forward to your fix.

btw- just pick up tripple of whatever you get so we can do mine before it breaks.

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post #16 of 33 Old 07-08-2010, 10:35 AM Thread Starter
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You've got it.

I like this guy's idea.....scroll about half way down.

http://www.wranglerforum.com/f33/not...y-44382-2.html

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post #17 of 33 Old 07-08-2010, 10:47 AM
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I think a sleeve with two washers would work well. You might be able to find a stepped washer which would work even better. Let us know what you find. I hate that plastic clip thing too.
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post #18 of 33 Old 07-08-2010, 01:06 PM Thread Starter
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Fastenal.....what a joke.

Ran over to my local Fastenal at lunch. Found a million things online with them, knew if they even had a fraction of that I could find what I needed. The place was a wreck, shit all over the floor you had to step around, empty paper towel rolls on the floor, packaging....a dump. Half the containers on the shelf were empty, the ones that had anything in them were nothing you need. No sleeves, no fittings, nothing. I thought this was supposed to be the grand daddy of fastener stores? It was pathetic.

Needless to say I'll be going to Lowes of all places, and see what I can find there. So, no updates.



^^ Need a couple of those.

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Last edited by BADGER; 07-08-2010 at 01:11 PM.
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post #19 of 33 Old 07-08-2010, 01:12 PM
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Needless to say I'll be going to Lowes of all places, and see what I can find there. So, no updates.
DO you have an Ace Hardware nearby? I find Ace to be better for actual hardware needs.
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post #20 of 33 Old 07-08-2010, 01:17 PM Thread Starter
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Yeah, got an Ace not too far from here. Maybe I'll check with those guys.

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post #21 of 33 Old 07-08-2010, 04:22 PM
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Quote:
Originally Posted by crusty1007 View Post
I have a fix.
It will require a couple hours to do & will set you back close to $200.00 but it eliminates the problem all together. Also, it works in the factory location with a better cable & rod end connections.

Shoot me an Email.

WTF? Just post the damn info already.

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post #22 of 33 Old 07-08-2010, 08:13 PM
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Quote:
Originally Posted by X-Defector View Post
Fastenal.....what a joke.

Ran over to my local Fastenal at lunch. Found a million things online with them, knew if they even had a fraction of that I could find what I needed. The place was a wreck, shit all over the floor you had to step around, empty paper towel rolls on the floor, packaging....a dump. Half the containers on the shelf were empty, the ones that had anything in them were nothing you need. No sleeves, no fittings, nothing. I thought this was supposed to be the grand daddy of fastener stores? It was pathetic.

Needless to say I'll be going to Lowes of all places, and see what I can find there. So, no updates.



^^ Need a couple of those.
My last visit to Fastenal I found what I needed, but they only had in qty of 500... I only needed 6. Went ahead and ordered online.

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post #23 of 33 Old 07-12-2010, 04:11 PM Thread Starter
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So here's the fix.....

https://www.jkowners.com/forum/showthread.php?p=481844

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post #24 of 33 Old 07-12-2010, 04:58 PM
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lol,,,Mine actually has a piece of clothes hanger twisted on it right now, But it works till I can or will fix it right!
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post #25 of 33 Old 07-13-2010, 04:58 PM
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How hard is it to access the shift-pawl on the t-case?
I want to fix this before it breaks...have my buddies machine shop making the bushing required...going to use washers/e-clip.
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