T-Case Linkage Popped Out, Any Tips? - JeepForum.com

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post #1 of 16 Old 08-16-2009, 01:08 PM Thread Starter
SkullV
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T-Case Linkage Popped Out, Any Tips?

Hey everyone,

Just bought a ZJ with a 3.5" IRO lift and a bunch of other IRO goodies already installed on it. I previously had a TJ which was all custom down to the custom stretched Matkins Extreme frame, the 7" suspension stretch, and the 11" suspension lift.

This ZJ T-case linkage has me stumped though. I could only engage 4wd Part time and nothing else so I went under and looked at the linkage. The Jeep has a 242 swap done with correct bezel and everything correct on the inside but it seems that the linkage has popped out of its bracket on the transmission side. There is a little green plug type deal that seems like it needs to be pushed back into the hole that it came from so everything can pivot properly. I suppose judging by this picture:



the piece that popped out is called the torque shaft bushing.

The problem is I cant get that little green plug to pop back in no matter what I do! Does anyone have any hints/tricks to get that thing back in there smoothly? Should I take the torque shaft bushing off the torque shaft and put it in THEN put the torque shaft into the bushing? Would this problem even cause me to not be able to get into 4WD full time/neutral/4WD low?

Thanks!


P.S. I did search first, and couldn't find a specific answer to this particular question. I have over 2000 posts on the CTS-V forum over on cadillacforums.come so I know how much you hate when people don't search first!


Last edited by SkullV; 08-16-2009 at 01:25 PM.
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post #2 of 16 Old 08-16-2009, 04:31 PM Thread Starter
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Bueller? Anyone have any ideas?
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post #3 of 16 Old 08-16-2009, 07:47 PM Thread Starter
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Come on guys I know someone has changed out that bushing before!
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post #4 of 16 Old 08-16-2009, 10:15 PM Thread Starter
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Annnnnyone?
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post #5 of 16 Old 08-17-2009, 02:37 AM
sandman
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those bushings are real hard. when i removed my t-case believe it or not the hardest part was removing the rod from the shifter plate. i would suggest using a pair of pliers or heating up the bushing.

1993 Jeep ZJ. 4.0
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post #6 of 16 Old 08-17-2009, 07:29 AM
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I had to wedge a pry bar between the frame and the linkage to get enough force on that puppy... Try getting some leverage on it with a pry bar... it should go in enough where you could then get some channel lock pliers up in there and squeeze it in the rest of the way.

Yard

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post #7 of 16 Old 08-17-2009, 07:45 AM
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If that bushing popped out, you'll want to replace it.
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post #8 of 16 Old 08-17-2009, 07:52 AM
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I took that off over the weekend. Took me a while to figure out how to get it back. I took my electricial pliers and put the cutters behind the plastic thing and used it to sort of pry off the plastic bushing. Then I took it and popped it into the hole on the transfer case. Then lined up the shaft with some help above and forced it in with a big ol flat head screwdriver against the transfer case till it popped in. That ended up working finally after 45 min of messing with it. Hope that helps if its still out.

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post #9 of 16 Old 08-17-2009, 08:41 AM
Zwildm30
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Mine popped out once when I first got my GC. Was a pain in the butt to get it popped back in. Had to pry against the bracket and it finally went in.

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post #10 of 16 Old 08-17-2009, 09:17 AM
HighLonesome
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Quote:
Originally Posted by SkullV View Post
!
There is a Mopar problem solving TSB for the linkage. Includes most of the parts in the diagram, including the bushing. Well worth it. Kolak can probably hook you up.
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post #11 of 16 Old 08-17-2009, 09:25 AM Thread Starter
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Quote:
Originally Posted by five.nein View Post
If that bushing popped out, you'll want to replace it.
The bushing looks like it's in perfect shape. The guy I bought it from said he dropped the T-case to change a seal a month ago so maybe putting this back in was just an oversight? It honestly looks like the bushing is brand new!
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post #12 of 16 Old 08-17-2009, 09:34 AM
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Quote:
Originally Posted by SkullV View Post
The bushing looks like it's in perfect shape. The guy I bought it from said he dropped the T-case to change a seal a month ago so maybe putting this back in was just an oversight? It honestly looks like the bushing is brand new!
If it was an oversight that's cool. Mine popped out after I swapped TCs. I'd press it back in and it would always pop out again. But it looked beat up too. Replaced it eight years ago and has been good to go. Just sayin
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post #13 of 16 Old 08-17-2009, 11:37 AM Thread Starter
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Greased the SH*t out of that bushing, popped it back in with a pry bar, readjusted the linkage and it works like a charm now! Thanks everyone!
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post #14 of 16 Old 08-30-2015, 09:34 AM
Lsuzj
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I know it's an old thread but I'm having the same issue with my 96zj where can I get a low budget upgrade so this don't happen again. My old jeep can't take 4 grand rocking it to get it spooled up enough for pt 4 hi to drag her *** off the bottom. And can I manually engage transfer case with vice grips if in dire need?
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post #15 of 16 Old 08-30-2015, 12:23 PM
kg6mov
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You can shift from under the jeep pretty easily. The novak cable shifter is the best permanent solution, but it's not what people around here call cheap. IMO, worth every penny: http://www.novak-adapt.com/catalog/shifters/sk2xz.htm

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