freight train

Hi everyone, I am a diehard 1st genner with two 1st gens as well as a 3rd gen. My 05 is a NV5600 4x4 truck with 72k on the odometer. Last weekend on a return trip from camping I heard what sounded like a large rock coming off a tire and hitting the undercarriage. Being I was towing a camper when I looked in the mirrors nothing was visible. Since the truck didn't act any differently I didn't think twice about it. Normally that sounds weird but I have 22.5" Alcoa's that do tend to through rocks. Anyways when I got home I was washing the truck and then vacuuming out and when I touched the 4x4 shifter I immediately noticed it wasn't attached to anything. I looked underneath and noticed the rod from the shifter to the t-case was missing. So I found a new rod on eBay and ordered new bushings from Napa. I cant believe the horrible design that when the bushings dry and get brittle the whole rod falls out and is lost. My question to you more known 3rd genners are is there a better solution to this? I was going to install the rod in a mock up and take it to a local machine shop so a solid version (that doesn't use bushings) that can be used with cotter pins and washers to hold it in. The same technology that has worked on 1st gens for over two decades. Does anyone know if there is maker that already makes what I am looking for? Thank you

WaywardSon

Can't provide any advice but just had the same experience. Bought an '05 4X4 with 78K about 2 months ago and immediately left for a 1400 mile trip through N.C. & the Outer Banks. I used 4WD once in the sand down there & all seemed normal...but noticed the rod for the transfer case was not operational when I got back. Lost and gone somewhere between Hatteras and Kentucky.
Replacement part w/bushings was $43 from the dealer...but did not include the bolt that locks all in place. I guess if I get 10 years out of this one I won't whine too hard:-)

freight train

I found a new rod on ebay for $21 shipped. Then bought two bushings from Napa. Once I got the rod I drilled two 1/8" holes on each end and installed a 1" key ring loop. On the main shaft not the ends where the bushings are. Once I installed I loosely zip tied both ends. One through a hold on the side of the NV5600 and the other around the t-case breather line. At least if it comes off now I will just have to replace the bushings. I still cant get over how bad of a design it is. I wish the ends were made to go through the bushings. I would drill a hole and tap it 1/4-20 and install a shoulder bolt with a washer. Or if it was made like a 1st gen design that had washers and cotter pins holding it in. The main difference is the rod on a 1st gen is a solid design, while the 3rd is an adjustable.