I had to get a new transfer case shift assembly today since the original one broke. I was 60 miles from home just finished off roading when I pulled the shifter out of 4 low at about 5 mph. Well the lever got jammed, wouldn't move and I was stuck in 4 low. Fortunately I was in a good area where I could work on my car. After wiggling around the shifter for 30 mins hoping it would free itself, I decided to open up the center console and investigate. I got down to the base of the transfer case assembly and saw 3 nuts holding on the handle. I removed the nuts and a ************* bolt fell into the transfer case. I quickly realized I shouldn't have removed the 3 nuts, but the 4 bolts around the 3 are the correct ones. Once I took the 4 correct ones off, I removed the shift handle and could see the shift levers and the gears of the transfer case. No ************* bolt in sight. I manually popped it in 2 hi and was so pissed I decided to drive home, hoping the bolt is not lodged between gears or gets thrown up and smashes a hole in my case. Made it home. Took off the side access panel on the xcase no bolt in sight. Used a flexible camera and located it from the top. Was able to get the bolt out with a magnet. Best feeling ever. Don't have to pull case and open it!
In inspecting the shift lever, there is a round plastic bushing that keeps the shifter aligned and precise. Apparently this piece is known to fail due to age and heat. Mine was completely disinigrated. None was left. My shifter was always sloppy, but I figured that's the way it was supposed to be. The bushing is not avail seperate. Only with the lever. Over $200 at the dealer. I found a good used one at the junkyard for $20.
Old with no bushing left.
New (used) with good bushing.
Gonna grease it up real good then install in a few.
Everyone should check their bushing because when they fail, all the bits fall directly into the xcase, getting ground up by the gears and mixed with the gear oil. Also the shifter will get sloppy and lock you out of certain gears!
