Novak transfer case shifter installation - JeepForum.com
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Unread 06-27-2009, 01:28 AM   #1
mudb8
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Novak transfer case shifter installation

novak has a t-case shifter that give the feel of control and precise shifting.
IMO, it's the one of the best ways to cure shifting problems from a body lift, t-case drop, and tummy tucks. not to mention gets rid of the Z gate.

just look at all the parts, which also wear out and move around...






here's the novak assembly as it comes out of the box...



I started by removing the console plastic to access the shifter mounts and removed both, the z gate shifter handle and the body bracket that hangs down under the rig which requires peeling the carpet back just a little..




next under the rig, the body bracket will be hanging, pull it off the shift lever, pry the shaft out of the tranny bracket, remove the 14mm nut from the t-case linkage and the 14mm nuts from the t-case bracket.




install the novak brackets onto the t-case ...




the linkage will be far to long as the unit comes, it needs to be moved to the forward most position for the 03 auto application this was installed on..
as you can see in this pic, with the t-case linkage also installed. also the throw can be shortened by using the upper most hole on the lever, raising the lever makes the throw longer.



in the above pic you can also see the mock up shifter handle bent to about where it needs to be to work...

remove the mock up handle, which is a Styrofoam tube with a solid wire inside to hold the shape, and start to bending the handle by heating it with a torch..






getting the right throw and bend to center the shift handle takes a while in the newer tj's due to the high console...

I actually got tired of messing with it and cut a small section out of the body..




the final bend took the top forward to miss the center console, after getting that done and figuring out the adjustment for the throw, it all worked and ended up not needing the small section of body cut out..

the customer was waiting while I messed around with the install for a couple hours, I had to hurry since I thought it would only take me an hour to do so I had to quit messing with the pics... sorry, no finished pics..

I used a truck mud flap and cut ti to size to cover the huge hole in the floor then put the console back together and and the 30 some dollar knob to go along with the $150.00 shifter..

the novak shifters work awesome once they are properly adjusted..

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Unread 06-28-2009, 12:07 PM   #2
DRZAP
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Same here. I spent more time bending the new rod and making it clear then I did installing the rest of it. I cut more out of the floor then I needed to. I have never had it pop out of 4 low ever since the install. 1 of the best upgrades I have done to my TJ.
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Unread 06-28-2009, 01:12 PM   #3
Unlimited04
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nice work. got any finished pics of the install? i like
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Unread 06-28-2009, 01:55 PM   #4
mudb8
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Quote:
Originally Posted by Unlimited04 View Post
nice work. got any finished pics of the install? i like
I'll get the finishied pics when it comes back in... it's the same rig I put the Avenger Supercharger in, it's at the shop from time to time.

I actually told him I could do it in about an hour so he was waiting, after 2hours had passed, he walked back in the shop to see how it was coming! I didn't even know he was waiting, he usually drops it off and goes abut his day so the pics got cut short....
__________________
I want your factory 07-up take-off/thrown out JK front/rear Lower Control Arms! Bent ones are perfect also as long as the bushings and cold cut rings are in good shape/useable


HighLine Hood Jeepers
TJ Adjustable Track bars
DIY highline fenders.... 34-37's under 0"-2.5" lifts
shock length, bumpstop extension, tire size chart click here
DIY shock shifters, more uptravel/better ride




2011 E-350 4x4 Van conversion

2006 Rubicon Unlimited

ASE Certified Master Tech/Fabricator @ jeepwest.com
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Unread 06-28-2009, 02:56 PM   #5
mcg311TJ
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Nice work...

Is the torch Idea recommended or is that your Idea?
By torching it, does that make the metal weak?

Could you use a pipe bender? ( if you got one )
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Unread 06-28-2009, 03:03 PM   #6
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Quote:
Originally Posted by mcg311TJ View Post
Nice work...

Is the torch Idea recommended or is that your Idea?
By torching it, does that make the metal weak?

Could you use a pipe bender? ( if you got one )

lol, I have both... the bender is a little difficult to use on bends so close together, the torch won't cause a problem unless you take an dunk it in water when it's hot, just let it air cool.
__________________
I want your factory 07-up take-off/thrown out JK front/rear Lower Control Arms! Bent ones are perfect also as long as the bushings and cold cut rings are in good shape/useable


HighLine Hood Jeepers
TJ Adjustable Track bars
DIY highline fenders.... 34-37's under 0"-2.5" lifts
shock length, bumpstop extension, tire size chart click here
DIY shock shifters, more uptravel/better ride




2011 E-350 4x4 Van conversion

2006 Rubicon Unlimited

ASE Certified Master Tech/Fabricator @ jeepwest.com
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Unread 06-28-2009, 03:07 PM   #7
Jerry Bransford
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Quote:
Originally Posted by mcg311TJ View Post
Nice work...
Is the torch Idea recommended or is that your Idea?
By torching it, does that make the metal weak?
Could you use a pipe bender? ( if you got one )
The shifter cane is hard enough that you're unlikely to bend it with anything cooler than a MAP gas torch. Don't even bother trying to bend it with a propane torch. Even with a MAP gas torch, my install helper and well muscled Marine Gunnery Sgt. Joe Bertain (Humboldt here on JF) was sweating bullets getting the Novak shifter cane bent properly.
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Unread 06-28-2009, 03:17 PM   #8
mcg311TJ
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Quote:
Originally Posted by mudb8 View Post
lol, I have both... the bender is a little difficult to use on bends so close together, the torch won't cause a problem unless you take an dunk it in water when it's hot, just let it air cool.
Ok, that's what I heard then.. Just remember hearing something like heating metal-break-weak-water-etc.. It's just a jumbled mess in my head

Quote:
Originally Posted by Jerry Bransford View Post
The shifter cane is hard enough that you're unlikely to bend it with anything cooler than a MAP gas torch. Don't even bother trying to bend it with a propane torch. Even with a MAP gas torch, my install helper and well muscled Marine Gunnery Sgt. Joe Bertain (Humboldt here on JF) was sweating bullets getting the Novak shifter cane bent properly.
Dang, guess that shifter cane is made from some strong stuff.. Good info to know. Thanks
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Unread 06-28-2009, 03:23 PM   #9
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Quote:
Originally Posted by Jerry Bransford View Post
The shifter cane is hard enough that you're unlikely to bend it with anything cooler than a MAP gas torch. Don't even bother trying to bend it with a propane torch. Even with a MAP gas torch, my install helper and well muscled Marine Gunnery Sgt. Joe Bertain (Humboldt here on JF) was sweating bullets getting the Novak shifter cane bent properly.


lol, I bent it with one hand...
__________________
I want your factory 07-up take-off/thrown out JK front/rear Lower Control Arms! Bent ones are perfect also as long as the bushings and cold cut rings are in good shape/useable


HighLine Hood Jeepers
TJ Adjustable Track bars
DIY highline fenders.... 34-37's under 0"-2.5" lifts
shock length, bumpstop extension, tire size chart click here
DIY shock shifters, more uptravel/better ride




2011 E-350 4x4 Van conversion

2006 Rubicon Unlimited

ASE Certified Master Tech/Fabricator @ jeepwest.com
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Unread 06-28-2009, 04:28 PM   #10
Jerry Bransford
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Quote:
Originally Posted by mudb8 View Post
lol, I bent it with one hand...
Yeah right.
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Unread 06-28-2009, 05:39 PM   #11
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Quote:
Originally Posted by mudb8 View Post
lol, I bent it with one hand after heating it cherry red with an oxy/acetylene rig...
fixed it for you.

I may be mistaken but I don't believe Novak sells this version any longer. The new one is cable operated and uses the stock shifter. Much simpler and easier install I heard.
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Unread 06-28-2009, 06:01 PM   #12
Jerry Bransford
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Quote:
Originally Posted by counselor View Post
I may be mistaken but I don't believe Novak sells this version any longer. The new one is cable operated and uses the stock shifter. Much simpler and easier install I heard.
If Novak has a new cable shifter, it's not yet on their website...

http://www.novak-adapt.com/catalog/kit_sk2x.htm
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Unread 06-28-2009, 07:16 PM   #13
mudb8
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Quote:
Originally Posted by counselor View Post
fixed it for you.

I may be mistaken but I don't believe Novak sells this version any longer. The new one is cable operated and uses the stock shifter. Much simpler and easier install I heard.


oh yeah, I guess I left that part out!

they still sell em I installed that a few weeks ago... if they use the stock shifter I'll never buy one. there's something about the feel of shifting a 205 t-case, that's what the manual novak shifter gives you.
__________________
I want your factory 07-up take-off/thrown out JK front/rear Lower Control Arms! Bent ones are perfect also as long as the bushings and cold cut rings are in good shape/useable


HighLine Hood Jeepers
TJ Adjustable Track bars
DIY highline fenders.... 34-37's under 0"-2.5" lifts
shock length, bumpstop extension, tire size chart click here
DIY shock shifters, more uptravel/better ride




2011 E-350 4x4 Van conversion

2006 Rubicon Unlimited

ASE Certified Master Tech/Fabricator @ jeepwest.com
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Unread 06-28-2009, 08:56 PM   #14
LJlunatic
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I bought one of the new cable actuated versions of the novak. It works great and was pretty easy to install. It doesn't use the old shifter, it uses the old shifter handle. So from inside the jeep it looks stock, but thats all. Its tight and easy to adjust, and no I think they haven't updated their site yet.
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Unread 06-28-2009, 09:06 PM   #15
Jerry Bransford
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That new cable shifter sounds good and is probably as a result of the difficulties some (like me) had getting the previous version shifting well.
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