Hello everyone!

Last week I and wife spent week down on Padre Island. Had a wonderful time. Ole Big Red performed flawlessly and on the trip down and back got about 13 mpg (hand calculated) pulling a 9000lb travel trailer plus gear and such.

Anyhow, we went down the beach several miles, in 4x4 4H through soft sand. Big Red handled it like it was on pavement...

However, when we returned and got back to pavement, I grabbed the lever to shift back to 2H. Imagine my surprise when the lever just flopped loosely back and forth.

I pulled over and slid under the cab to find that the rod that connects the cab lever to the transfer case lever was totally MIA!!! I was able to grab the transfer case lever and pop it back into 2H.

I am gonna fab up a new connector out 1/4 inch aluminum and bolts which i can cotter pin to avoid this happening again.

Was wondering if anyone else had this happen. I rarely use 4X4 and had never checked the connecting rod before.

Thoughts/Comments???

 

The bushing on the linkage is notorious for failing. Fab it up if you want, otherwise replace.

 

They do fail quite a bit, allowing the connecting rod to fall off.

 

I had the same incident happen to me. Fortunately it was in my driveway and only one bushing gave up the ghost. I now carry a couple spares with me and replace avery 24 months and have not had a problem since.

The only concern I have about the metal bushing to the shifter and shift arm is there might be a bit of a buzz in the cab when you are driving. Probably not noticeable. Keep us posted on how the new shifter setup works and if there is any noise in the cab when driving.

L8r,...........dogger

 

I keep an eye on mine and been meaning to grab a spare just in case. I guess I'll grab one when I'm getting the spare #4 line

I wonder if the bushing would last longer if it was lined with a metal bushing (rubber on the outside to dampen vibration, metal inside for strength)?

 

Thanks for all the replies. I will report back with photos once I have it replaced.

 

Funny -- I had the same thing happen to me while returning on I-10 from Huntsville last weekend! Running down the road, heard something that sounded like road trash getting kicked up. Got home and accidentally bumped the 4WD shifter in the truck and it was flopping all over the place. Looked underneath and it was gone, gone, gone!
I was thinking of fabbing one as well to replace it, but don't know the dimensions (length) of the stock one. I have a good friend with a machine shop at my disposal - may as well try and make something that will last over the OEM version. I would have thought they would have had some retaining clip to prevent total loss of the linkage.
Anyone have the dimensions? I would measure it myself, but I don't have the part!

 

HHauler, I'll go out and measure mine for you and post back this evening when it cools off.

 

Thanks!!!

 

It ended up raining yesterday evening then the power went out for awhile But got it this morning.

Rod info:
- mild steel (magnet sticks)
- .375" diameter
- 12.5" long total
- 10" between pivot holes on center
- 72* angle on the bracket from the cab

In the pic, the front of the truck is the left end of the drawing.

Inspecting the grommets on the brackets, the front grommet is pretty smashed up. Mine will probable go out next use or two. Ought to at least safety wire it up. Drill a hole a cotter pin it maybe so I don't lose it altogether on the road at least.

 

Thanks for the detailed info Shorts! I am going to fab one up instead of getting the stock one being that they have a bad design. Appreciate the help -- send some of the rain our way!

 

You're welcome. Post some pics when you get yours fabbed.

Will try to shoo some rain your way too.

 

Thanks for the intel Shorts! The wife just called me and told me our truck just did the same thing. She was moving some round bales with it, and when she went to pull it back out of 4WD, the shift was all sloppy and the truck stayed in 4WD. Guess I know what I am doing tomorrow.

-Joe

 

Got my replacement (stock) bushings and I will be fabbing a custom linkage over the next two weeks with a buddy. I will post pics once completed.

 

Back in the dark ages when I had my Jeep CJ, I replaced my clutch linkage with a length of threaded rod and rod ends. After it was complete and the joints were greased, it I found it was adjustable and ran smoother.

Check these out...

http://www.mcmaster.com/#rod-ends/=oelzl9

Oh, and don't forget to double nut each joint.