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4WD Systems Transfer Cases & Locking Hubs.

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Old 08-13-2018, 10:48 AM   #11
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It really shouldn't be that hard to make your own levers. Some flat-stock or w piece of weld plate and some round stock. Trace, cut, weld, drill, bend.
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Old 08-13-2018, 10:49 AM   #12
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I found the thread on another site http://<br /> https://www.explorerfo...t-case.280143/ doesn't look too difficult I really don't know where I'm headed with this, because I may still go for the shiftster, or make my own to replace the electric motor.
But there are tons of manual transfer cases out there but they're all without linkages.
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Old 08-13-2018, 07:59 PM   #13
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Ordered bushing - by the way, what holds this 12.00 piece of plastic in place?
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Old 08-13-2018, 08:04 PM   #14
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If it's plastic, it's probably formed in such a way that it snaps in place and retains itself.... Until worn out.

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Old 08-14-2018, 09:40 AM   #15
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thats what I was thinking - we shall see.
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Old 08-18-2018, 09:27 PM   #16
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Default Success!

Installed new bushing, loosened 30mm big nut (thats what I had) and 14mm smaller nut to obtain clearance to slide new bushing onto fork. The pin lever (that is mounted to tcase) was super loose which explains why I lost my bushing in the first place. I realigned, added loctite blue and tightened, and lubed gate and associated parts. Tcase lever is now tight, smooth with perfect engagement - that bushing and tightening the pin lever made a massive difference - check yours for looseness and loctite it -thanks for all the help!
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