Transfer case shifter bushing busting

[Renedave]

I've been running with the transfer case cable zip tied to the shifter arm since the bushing decided to give out on me in the fall, and finally decided to put the replacement bushing on yesterday morning. No problem, get under there and snip the zip ties off, remove the remnants of the old bushing, and coat everything involved with white lithium grease to simplify the process. Easy, right? Except now, the bushing refuses to go in the cable eyelet. I grab some channel locks to help convince it, because now it's about 35 degrees and raining, I'm working in the driveway because the garage is too full of other projects, and I want this done in a hurry. One ham ****** squeeze of the locks and there's an unsatisfying release of them feeling like they're holding on to anything. Stupid me has managed to snap the entire eye off the cable. Crap.

After looking around as far as I can tell my only option is to order an entire shifter handle and cable assembly. Is there no option for just replacing the cable end or cable? The job doesn't look too hard more of just a PITA, my biggest concern is actually how to get the orange clip out that holds the cable under the Jeep without breaking it. Any advice on that?

 

[rockymountain]

I've been running with the transfer case cable zip tied to the shifter arm since the bushing decided to give out on me in the fall, and finally decided to put the replacement bushing on yesterday morning. No problem, get under there and snip the zip ties off, remove the remnants of the old bushing, and coat everything involved with white lithium grease to simplify the process. Easy, right? Except now, the bushing refuses to go in the cable eyelet. I grab some channel locks to help convince it, because now it's about 35 degrees and raining, I'm working in the driveway because the garage is too full of other projects, and I want this done in a hurry. One ham ****** squeeze of the locks and there's an unsatisfying release of them feeling like they're holding on to anything. Stupid me has managed to snap the entire eye off the cable. Crap.



After looking around as far as I can tell my only option is to order an entire shifter handle and cable assembly. Is there no option for just replacing the cable end or cable? The job doesn't look too hard more of just a PITA, my biggest concern is actually how to get the orange clip out that holds the cable under the Jeep without breaking it. Any advice on that?

If you’re talking about the clip that snaps in on each side of the cable when it slides up into the bracket, all you need to do is get something to grab each side and pull down. I used a cotter pin removal tool which is basically like a screwdriver hooked on the end and pointed.
I also posted over on the other thread and I tried getting the bushing in with it still up there but there was no way to get my hands up there in a way to do any good. Check the “what did you do to your Jeep today” thread and you’ll see I took it out in order to drop the end down to get to it.


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[Renedave]

It's the cable retainer clip. This part: https://www.morris4x4center.com/mopar-transfer-case-shift-cable-retainer-clip-68018106aa.html

I've got a whole set of "dentist's picks" in multiple angles, so I'll put them to good use.

Thanks, I'll check out the other thread. I've removed the crossmember a couple times to replace cats that I smashed while wheeling, but sure would like it if I didn't have to do it again! And no doubt, not being able to get my meathooks in a good place to install the bushing was a big contributor to me screwing this up.

 

[wheeee32]

How many miles are on your KJ? Just curious so I have an idea when to start thinking about replacing mine and not have it break on me when I actually need it.

 

[Renedave]

How many miles are on your KJ? Just curious so I have an idea when to start thinking about replacing mine and not have it break on me when I actually need it.

It just hit 160K miles, 11 years old when the bushing went. It had good life.

The new shift assembly showed up last night, and the bushing is pre-installed. One less thing for me to screw up!

 

[rockymountain]

It just hit 160K miles, 11 years old when the bushing went. It had good life.

The new shift assembly showed up last night, and the bushing is pre-installed. One less thing for me to screw up!

can you post a pick of it? in particular the bushing on the end of the cable?

 

[Renedave]

I'll take a pic on Monday when I'm back in town, but it looks exactly like this one (which is the same one I broke the eyelet on):

https://www.amazon.com/gp/product/B01BX3M514/

 

[HoosierJeeper]

Does any of this apply to the Selec trac tcase? I think the Selec Trac has a different setup the Command trac one?

 

[ltd02]

Does any of this apply to the Selec trac tcase? I think the Selec Trac has a different setup the Command trac one?

I know the bushing at the end is the same. I bought the one listed for the 231 and it fit on my 02 with the 242. Never saw a separate listing for that bushing on a 242.

 

[rockymountain]

I'll take a pic on Monday when I'm back in town, but it looks exactly like this one (which is the same one I broke the eyelet on):

https://www.amazon.com/gp/product/B01BX3M514/

That's why I would just like to see your assembly. That doesn't fit mine and seems to have an entirely different cable end and bushing. Just trying to determine a let people know there is a difference in some of these.

My bushing is this one:
https://www.ebay.com/itm/Fits-Jeep-...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

 

[Renedave]

Here’s the bushing end of the shifter. No way I can see the blue one in your pic fitting in there.

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[rockymountain]

Here’s the bushing end of the shifter. No way I can see the blue one in your pic fitting in there.

You must be registered for see images attach

Yeah that’s totally different. So there’s two kinds of shifter cables. I guess either would work but you have to know which one you have to get the correct bushing.


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[rsscoggins]

That's why I would just like to see your assembly. That doesn't fit mine and seems to have an entirely different cable end and bushing. Just trying to determine a let people know there is a difference in some of these.

My bushing is this one:
https://www.ebay.com/itm/Fits-Jeep-...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

Timely thread as I need to replace this bushing on my son's Liberty. We are working on the 2002 Liberty that we bought for my son that has 75k miles on it. We bought it in January and when test driving, I checked to make sure it shifted into 4wd high and low. It did as I could see the light on the dash PLUS, you can feel the difference when driving.

This past weekend, I pulled the front drive shaft as I need to replace the pinion seal on the front differential and replace the rear CV on that front driveshaft. While under there, I noted that the transfer shifter cable was a little loose. It was just sitting there loose on the little shaft with lots of play. I am not sure if the bushing was missing when we bought it or if my shifting it into 4wd caused the original 16 year old bushing to disintegrate...either way, it's not there.

I had the same issue with my Jeep JK unlimited. A $2 bushing fixed that up and infact, I had a spare in my box of parts. Tried that bushing and no go - the size of the bushing doesn't even fill the hole in the end of the cable and it would still be sloppy. The part number on the bag was Crown# 68064273AB.

I did some research and see that the bushing for the Liberty is unique to the Liberty and damn expensive for what it is! Part number that I think I need is 68001899AA and the cheapest I can find is on Amazon Liberty Transfer Case Bushing

I have seen similar ones for a Dodge RAM or Dakota but they have a different part number (and are cheaper). Hell Dorman even makes one for them. The one you linked to on the eBay auction looks like it will last longer.

My biggest question is - HOW ARE THESE RETAINED? Is there anything holding it in place instead of friction? Did you buy the eBay one and does it work as the original does?

How hard is it to get the bushing back into the end of the shifter cable?

 

[rockymountain]

Timely tread as I need to replace this bushing on my son's Liberty. We are working on the 2002 Liberty that we bought for my son that has 75k miles on it. We bought it in January and when test driving, I checked to make sure it shifted into 4wd high and low. It did as I could see the light on the dash PLUS, you can feel the difference when driving.

This past weekend, I pulled the front drive shaft as I need to replace the pinion seal on the front differential and replace the rear CV on that front driveshaft. While under there, I noted that the transfer shifter cable was a little loose. It was just sitting there loose on the little shaft with lots of play. I am not sure if the bushing was missing when we bought it or if my shifting it into 4wd caused the original 16 year old bushing to disintegrate...either way, it's not there.

I had the same issue with my Jeep JK unlimited. A $2 bushing fixed that up and infact, I had a spare in my box of parts. Tried that bushing and no go - the size of the bushing doesn't even fill the hole in the end of the cable and it would still be sloppy. The part number on the bag was Crown# 68064273AB.

I did some research and see that the bushing for the Liberty is unique to the Liberty and damn expensive for what it is! Part number that I think I need is 68001899AA and the cheapest I can find is on Amazon Liberty Transfer Case Bushing

I have seen similar ones for a Dodge RAM or Dakota but they have a different part number (and are cheaper). Hell Dorman even makes one for them. The one you linked to on the eBay auction looks like it will last longer.

My biggest question is - HOW ARE THESE RETAINED? Is there anything holding it in place instead of friction? Did you buy the eBay one and does it work as the original does?

How hard is it to get the bushing back into the end of the shifter cable?

The bushing retains it. On the outer side of the bushing, the hole is small and sorta snaps on. Heck, the cable sat there without a bushing, mine for about 4 years without the bushing and I never had an issue except for it being sloppy. The bushing is a bit difficult to get in the end of the cable but I got it by using Petroleum jelly. Also lowered the cable down so I could get to it by taking it out of the bracket it’s in.
I put the bushing on the linkage post before anything and it was on pretty snug. It was difficult to pull back off.


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[rsscoggins]

The bushing retains it. On the outer side of the bushing, the hole is small and sorta snaps on. Heck, the cable sat there without a bushing, mine for about 4 years without the bushing and I never had an issue except for it being sloppy. The bushing is a bit difficult to get in the end of the cable but I got it by using Petroleum jelly. Also lowered the cable down so I could get to it by taking it out of the bracket it’s in.
I put the bushing on the linkage post before anything and it was on pretty snug. It was difficult to pull back off.


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Excellent, I will order one tomorrow!


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[Renedave]

Excellent, I will order one tomorrow!

Dang, I wish I'd checked this earlier. I have one of the larger bushing sitting in my garage with no place to go and I'd rather send it to someone that needs it than toss it or stow it away and forget about it.

 

[rsscoggins]

Dang, I wish I'd checked this earlier. I have one of the larger bushing sitting in my garage with no place to go and I'd rather send it to someone that needs it than toss it or stow it away and forget about it.

If you are going to bin it, I will take it off your hands.

I will PM you.



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[Renedave]

If you are going to bin it, I will take it off your hands.

I will PM you.

Sure, PM away.

 

[blackhawk]

I tried this three years ago and no problem at all.

 

[bajasoobnut]

Timely thread as I need to replace this bushing on my son's Liberty. We are working on the 2002 Liberty that we bought for my son that has 75k miles on it. We bought it in January and when test driving, I checked to make sure it shifted into 4wd high and low. It did as I could see the light on the dash PLUS, you can feel the difference when driving.

This past weekend, I pulled the front drive shaft as I need to replace the pinion seal on the front differential and replace the rear CV on that front driveshaft. While under there, I noted that the transfer shifter cable was a little loose. It was just sitting there loose on the little shaft with lots of play. I am not sure if the bushing was missing when we bought it or if my shifting it into 4wd caused the original 16 year old bushing to disintegrate...either way, it's not there.

I had the same issue with my Jeep JK unlimited. A $2 bushing fixed that up and infact, I had a spare in my box of parts. Tried that bushing and no go - the size of the bushing doesn't even fill the hole in the end of the cable and it would still be sloppy. The part number on the bag was Crown# 68064273AB.

I did some research and see that the bushing for the Liberty is unique to the Liberty and damn expensive for what it is! Part number that I think I need is 68001899AA and the cheapest I can find is on Amazon Liberty Transfer Case Bushing

I have seen similar ones for a Dodge RAM or Dakota but they have a different part number (and are cheaper). Hell Dorman even makes one for them. The one you linked to on the eBay auction looks like it will last longer.

My biggest question is - HOW ARE THESE RETAINED? Is there anything holding it in place instead of friction? Did you buy the eBay one and does it work as the original does?

How hard is it to get the bushing back into the end of the shifter cable?

I just went through this myself, the bushing I had to get was 68001899AA btw and it was almost 39 bucks at the stealership!