Shifter bushing elimination fix possibly?

Discussion in 'Fabrication' started by bajasoobnut, Oct 7, 2020.

  1. bajasoobnut

    bajasoobnut New Member

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    Hey guys, I am now starting to look initially into either modifying or even fabricating a new setup for the transfer case end of the selector system. I replaced the shifter/cable assembly on my 03 to the newer shift assembly from what I believe was a 05 that was in the pick-n-pull near my place. I put in a new bushing as well and it failed and yeeted out a little bit after installation and after finding out that it was a poor design with failures galore I decided to look into it more. I haven't done any measurements yet but I am thinking of removing the stud on the lever arm and either making a revnut or possibly new arm with a tapped hole and using a custom made brass bushing and shoulder bolt system. Possibly looking at how to redo the cable end to take a heim joint possibly.

    So, just want to know what you guys think about this idea.
     
  2. tommudd

    tommudd Moderator Staff Member Moderator

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    If it failed you have other issues as well possibly, not a bad design, parts just wear out
     
  3. bajasoobnut

    bajasoobnut New Member

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    As I stated I replaced the shifter cable system with one from a 05 and this is in a 03, the bushing is the same one that is used in 07 and up wranglers and I have ran across many issues on other forums with bushing failure. The reason why I had to replace the cable and all was because I had a sleeve failure where it separated from the shifter side trunnion, was a bitch to get it shifted back into 2wd when that happened btw. So I am looking at a better system where you don't have to use zip ties or other means of keeping things together. Also I haven't shifted it into 4wd since I did that replacement so it all came apart while just driving around.
     
  4. tommudd

    tommudd Moderator Staff Member Moderator

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    Well that one sentence changes everything then
    But if you got it from a junk yard then possibly it was bad and just looked OK, before you installed it
    Out of my 3 ( with a combined mileage of over 550,000 miles on them) and over 150 KJs or so that I have worked on , never had an issue with the cable or any breakage
    And all have been used a lot , so just wondering you know


    good luck on your quest though ;)