Transfer Case Shifter Resto

[theShaytoon]

Pulled apart the Transfer Case Shifter to clean it up and make pretty...the plastic cup circled is broken and I would like to replace it. It's a $10 part, but I didn't know if you can take the bottom part of the shaft apart from the rest. Before I put it in the vise and put some heat to it, is that shaft all one piece because the top is welded to the silo looking part?

 

[Napalm00]

I actually don't think this is removable. I just rebuilt mine as well recently and had to reuse the broken cracked one just like this. I couldn't figure out how to get it off either.

The bottom shaft and the top shaft are actually separate if I recall. But I think it's vulcanized rubber inside of that bell-shaped welded on housing.. so if you remove the bottom shaft from the upper shaft to take that piece out and replace it I don't think you can get it back together easily.

 

[theShaytoon]

I actually don't think this is removable. I just rebuilt mine as well recently and had to reuse the broken cracked one just like this. I couldn't figure out how to get it off either.

The bottom shaft and the top shaft are actually separate if I recall. But I think it's vulcanized rubber inside of that bell-shaped welded on housing.. so if you remove the bottom shaft from the upper shaft to take that piece out and replace it I don't think you can get it back together easily.

Yip...there is definitely a rubber filling in the bell shaped housing. The part diagrams I've seen don't actually have the bell housing piece, it is just a straight shaft...but this shifter is from a Disco I, so I thought maybe there was a way to take it apart...

 

[Napalm00]

Both defender shifters that have remanufactured here at the house are exactly like this one

 

[hillstrubl]

Is plastic welding or epoxy an option?

 

[theShaytoon]

Is plastic welding or epoxy an option?

Probably...there is recess for a c-clip, and it is the chipped portion. I went to the salvage yard and yanked another shifter out, $24 and 30 minutes...if that one is broken too, then I will glue it up, maybe use some duct tape.

 

[hillstrubl]

Probably...there is recess for a c-clip, and it is the chipped portion. I went to the salvage yard and yanked another shifter out, $24 and 30 minutes...if that one is broken too, then I will glue it up, maybe use some duct tape.

NEEDS MORE BAILING WIRE!

 

[erover82]

If you really want to replace that plastic bit, I'd separate the shafts, remove the rubber filling, replace the plastic bit, fill with two-part polyurethane rubber (aprox. A70 or D20 durometer), reassemble, and let cure.

 

[Napalm00]

So I had this spare that are removed from my truck when I swapped over to my new trans and transfer case. This is the original shifter from my '83 so it's really really early. You can see here if you look carefully the shift rod itself does not have the rubber two-piece shift shaft that yours does. It also has that little center return spring that is shaped like a bow on the upper part of the housing.

Plastic clip in this one is good.The complaint I always had with this particular one was that the angle of the shaft put the shifter off and to the left a little bit. And with my truck setup being originally a single cab it put the transfer case shifter very close to the front of my center cubby. The later model shifters stick up more vertically and made it easier for me to shift the transfer case. Hence the swap.

I paid 50 shipped I think for the other shifter. If you want this one plus the clip I do the same for you.I could take more pictures and post them here if you're interested.My plan always was before swapping these shifters over to just remove the shift rod from this assembly put it in a vise and then bang it into the position that I wanted it.

 

[rocky]

How’s the rubber gaiter where the shifter goes into the box? I discovered mine was Mia shortly before the box destroyed itself.

 

[Napalm00]

It's there and hard as a rock. Replacement item is avail. this one has no cracks it think . I'll send more pics