3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

4wd Transfer case to gear shifter upgrade

Thread Tools
 
Search this Thread
 
Old May 2, 2025 | 07:18 AM
  #1  
high bid's Avatar
Thread Starter
Registered User
15 Year Member
Liked
 
Joined: May 2007
Posts: 2,160
Likes: 10
From: Sarasota, FL
4wd Transfer case to gear shifter upgrade

The bracket that connects the transfer case to the floor 4wd selector seems to fall off, come loose and/or break off randomly. Not sure what the original factor bracket that connects these two looks like exactly but this is the second time it's missing and gone, thus leading to the floor 4wd shifter just flopping around. So if you have a 03-07 2500 and have the 4wd floor shift/manual selector, this fix might be for you. I looked on other sites but rely on DTR for lots of ideas, fixes and tips and wasn't able to find anything. So with this write up I found some of the parts ideas on other sites and hopefully these details help.
Sourced parts from McMaster-Carr (super fast to ship)
(2) 3/8 ball-joints RH thread
(1) 3/8 Internally threaded connecting rod- 9" length
(4) flat fender washers
(2) locking nuts
Measure distance to confirm the length from the shifter to transfer case connection points. I had to cut/trim both ball-joints and the connecting rod about 1/2" each for approximate best fit. I used a small piece of hose as internal grommet for the connection points of both the floor selector and the transfer case




. Test fit, adjust to the correct length for actual 4wd engagement. I needed to adjust the length about 1/4" but when tested 4wd engages and now works again.
Pretty easy overall vs buying the same factory part to have it fall off again. Cost was about $53 and an hour or so to cut the
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
mattym
24 Valve Engine and Drivetrain
6
Jan 22, 2016 09:23 PM
mtdoragary
12 Valve Engine and Drivetrain
4
Jul 8, 2014 02:33 PM
csramsey640
3rd Gen Engine and Drivetrain -> 2003-2007
2
Sep 30, 2011 11:59 AM
Halibrand
3rd Gen Engine and Drivetrain -> 2003-2007
3
Oct 19, 2008 12:09 AM




All times are GMT -5. The time now is 01:23 AM.