Transfer Case Linkage Fix - JKowners.com : Jeep Wrangler JK Forum
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post #1 of 15 Old 09-22-2012, 07:01 PM Thread Starter
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Transfer Case Linkage Fix

As some of you have probably learned the transfer case linkage on our JK's isn't very well designed. Thought Id show an easy way to fix it that cost about $10.00.

I got these from Oreillys but I'm sure you can get them at just about any auto parts store.


First I dropped the transfer case skid to get access to the broken linkage.


Now taking the smallest bushing use a 5/16" drill bit and use it to open up the hole in the bushing.


After you drill out the bushing put it into the opening on the shift linkage cable and slide it onto the stud that's on the shift lever so that the flat end is facing out, away from the transfer case.

Next find the E-clip that measures 3/8"


Now you simply push the E-clip on to the shift lever in the grove that is already on the stud.


That,s it, takes about 20 min to do and there's enough to fix both ends. Only difference is when using the bushing that is the next size up you'll need to shave down the outside of it so it will fit into the opening on the shift linkage. Been running this fix on the other end of my shift linkage for over a year now with out a hitch.
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post #2 of 15 Old 09-25-2012, 08:53 AM
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Great write up! Mine just broke at the shift lever when in 4Lo and after wheeling had to go under the Jeep and through the t-case lever forward to go home. Not so much fun with the exhaust right where your arm needs to go. I will be doing this to my rig this weekend. Thanks again for the write up!

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post #3 of 15 Old 09-30-2012, 07:46 AM
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Thanks again for the write up! Took about an hour for both...Including beer brakes and it raining outside.

FYI, In the bushing kit there is only one of the smallest bushings that work. I had to sand down, outside diameter, the second to the smallest bushing to do both sides. You do have enough e clips. Thanks again!

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post #4 of 15 Old 11-04-2012, 01:23 AM
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Doing this project next weekend

08 2Door Red Rubicon. Rock Krawler 5.5 Longarm Coilover, Polly rear Coilovers. AEV hood & wheels, 37"KM2s, JE Reel 1350 shafts, 5.38 Yukon gears, Superior axles, Shrockworks stubby, Fab Fours rear, sPod, Rebel Offroad brakes, Warn winch and lots more.

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post #5 of 15 Old 11-04-2012, 04:09 AM
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So this will fix my hard time trying to put it into 4hi and lo?0


Sent from my iPhone 5!

-Marc
2010 JKU -- 3.5" RE Lift -- EVO LCAs -- ARTEC Truss and TB mount -- 17" Procomp 7069 -- 37" Maxxis Treps -- Heated Trucklite Headlights -- Synergy Drag flip -- Synergy TR -- Synergy bj's-- EVO 1/4 Pounder -- EVO Tire Carrier -- 4 gal rotopax -- TF Third Row -- China AEV Snorkel

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post #6 of 15 Old 11-04-2012, 04:25 AM
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Quote:
Originally Posted by JKUnlimitedSport_2010 View Post
So this will fix my hard time trying to put it into 4hi and lo?0


Sent from my iPhone 5!
No. That's user error imo. This will keep the bushing from popping and your shifter going limp.

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post #7 of 15 Old 11-04-2012, 04:39 AM
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Really goody... User error... I know how to use the t-case system... So I will find another solution! Thank you!


Sent from my iPhone 5!

-Marc
2010 JKU -- 3.5" RE Lift -- EVO LCAs -- ARTEC Truss and TB mount -- 17" Procomp 7069 -- 37" Maxxis Treps -- Heated Trucklite Headlights -- Synergy Drag flip -- Synergy TR -- Synergy bj's-- EVO 1/4 Pounder -- EVO Tire Carrier -- 4 gal rotopax -- TF Third Row -- China AEV Snorkel

Coming up:
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14 Bolt rear ARB w/ 5.38
EVO Long Arm
40/42” MTR's
17" Spyderlock Beadlocks
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post #8 of 15 Old 11-04-2012, 04:45 AM
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Quote:
Originally Posted by JKUnlimitedSport_2010 View Post
Really goody... User error... I know how to use the t-case system... So I will find another solution! Thank you!


Sent from my iPhone 5!
I can get mine to shift pretty smooth, so yes really. It is not a fully synchronized system between 4hi and 4lo. The transfer case linkage breaking is primarily due to people trying to force the shifter, rather than slowly rolling and letting it fall in. A simple cable linkage isn't going to cause a hi to low problem, if you tried to do it by hand on the transfer case lever you could get it to bind up..but what the hell do I know? Good luck with your transfer case hi/lo internal synchronization mod. I'm not trying to be an ass, but I rather not see you waste your time and effort trying to "fix" something that isn't there.

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Last edited by Goodysgotacuda; 11-04-2012 at 04:53 AM.
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post #9 of 15 Old 11-04-2012, 04:50 AM
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Yes user error, I have a rubicon and after many times of practicing over and over, I can now constantly shift it from 2wd, to 4wdh, then 4wdl and back with just two fingers. It's like a woman, you have to find its sweet spot. And no, spitting on it won't help.
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post #10 of 15 Old 11-04-2012, 07:52 AM
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I am sorry for before... I went out and gently put it into 4hi and 4lo... Apparently I was trying to slam it in.... Damn it... Thanks for helping! Haha should this fix be done for precautions?


Sent from my iPhone 5!

-Marc
2010 JKU -- 3.5" RE Lift -- EVO LCAs -- ARTEC Truss and TB mount -- 17" Procomp 7069 -- 37" Maxxis Treps -- Heated Trucklite Headlights -- Synergy Drag flip -- Synergy TR -- Synergy bj's-- EVO 1/4 Pounder -- EVO Tire Carrier -- 4 gal rotopax -- TF Third Row -- China AEV Snorkel

Coming up:
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14 Bolt rear ARB w/ 5.38
EVO Long Arm
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post #11 of 15 Old 11-04-2012, 07:54 AM
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Quote:
Originally Posted by JKUnlimitedSport_2010 View Post
Haha should this fix be done for precautions?


Sent from my iPhone 5!
I did, it's a good idea. Mine was a little different but this should do it just fine.

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post #12 of 15 Old 10-14-2015, 11:48 AM
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Great step-by-step instructions. It took all of about 15 minutes to repair mine. Thanks!
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post #13 of 15 Old 05-23-2016, 11:15 AM
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Thanks for the pics!

Question: I just bought a 07 rubicon 2dr and broke the transfer case linkage the moment i got it into the driveway FML.

How it happened: I shifted from 2h to 4h and to 4L while stationary. The case proceeded to freeze up and had to force it into neutral. From Neutral it refused to go into any other drive mode and I eventually snapped the linkage trying to get out of neutral.

The Jeep became stuck in neutral and i had to call tow.

Luckily the dealer warranty is covering the fix but I'm wondering if I need to be concerned about any other damage that resulted from the freeze up? Also, how do i avoid this in the future?

I saw a little bit of fluid dripping from the bottom of the transmission after this happened did I possibly blow the transmission or the transfer case? Thanks for the help. -Joe
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post #14 of 15 Old 05-23-2016, 11:43 AM
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I've had the same zipties holding on for about 5 years now. On both the transfer case side and inside with the shifter. Never had an issue.
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post #15 of 15 Old 05-23-2016, 12:37 PM
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Quote:
Originally Posted by jgdyer90 View Post
Thanks for the pics!

Question: I just bought a 07 rubicon 2dr and broke the transfer case linkage the moment i got it into the driveway FML.

How it happened: I shifted from 2h to 4h and to 4L while stationary. The case proceeded to freeze up and had to force it into neutral. From Neutral it refused to go into any other drive mode and I eventually snapped the linkage trying to get out of neutral.

The Jeep became stuck in neutral and i had to call tow.

Luckily the dealer warranty is covering the fix but I'm wondering if I need to be concerned about any other damage that resulted from the freeze up? Also, how do i avoid this in the future?

I saw a little bit of fluid dripping from the bottom of the transmission after this happened did I possibly blow the transmission or the transfer case? Thanks for the help. -Joe
Highly unlikely that you broke the transmission or the transfer case. I am sure that the linkage broke way before you did any damage to them.
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