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Jeep TJ Transfer Case Linkage Popped out

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3.7K views 5 replies 5 participants last post by  biffgnar  
#1 ·
My transfer case linkage popped out a few days ago after I put in my 4 terraflex 4 inch lift kit which included a transfer case drop. After the transfer case drop the the bolts of the left side of the transfer case came out which caused it to hang I was able to fix the transfer case mounting problem. However I have no idea how to even force the linkage back in.

~signed worried offroader
 

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#2 ·
Once that linkage gets messed up fixing it is a real roll of the dice. The bushings get old and stretched. Dealer used to offer a refurbishment kit, but I don't think available any longer. Good time to take a look at the aftermarket options for shift linkage. Best option out there are the cable shifters (I'd buy Savvy). They work great, although are more $$s than some people looking to spend. There are some aftermarket bracket designs though (e.g. Advanced Adapters, Teraflex) that are much cheaper and work fine.
 
#3 ·
Unbolt the shift bracket (14) from the tub, reinsert the end of the transfer case shift bellcrank (17) into its bushing (7) in the bracket, then bolt the bracket back to the tub being careful to not let the bellcrank fall out again. You will most likely want a helper, but it is possible to do this on your own. Alternatively, you can unbolt the skid plate and lower the transfer case sufficient to get the shift bellcrank to line up with the bushing again. The other option would be to try to pop the bellcrank out if its bushing in the transfer case side bracket (16), reinsert it in the tub side bracket bushing, then snap the bellcrank back into the transfer case bracket... good luck with that method if you try.
 

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