4WD shifter

[mudrunner]

So I was noticing my 4WD shifter seems a little funny to me the other day. I suppose I should look at it since I can physically rotate it about 90 DEG. Am I right to assume I should not be able to do this. I imagine it should be very tight in its location and shift with out moving around a lot.

[ES_97Sport]

Feb 24, 2014 1:33:42 GMT -5 mudrunner said:

So I was noticing my 4WD shifter seems a little funny to me the other day. I suppose I should look at it since I can physically rotate it about 90 DEG. Am I right to assume I should not be able to do this. I imagine it should be very tight in its location and shift with out moving around a lot.

Correct. It shouldn't rotate at all. The 5-speed transmission shifter is a ball and cup assembly, but the t-case shifter is a looks like a ball that's had the round on both sides machined off 'till its about 1/4" thick. That sounds like the bushing is broken, it isn't installed correctly or the plunger spring assembly is broken/shot. Maybe the spring. The plunger should hold it tight in the arm.

Edward

[mudrunner]

Alright guess I know what I am doing wednesday. It's okay I was going to install my HD radio tuner any way.

[mudrunner]

I also noticed it doesn't always light up my 4wd lights either...

[dclambertt]

Evidently these bushings are prone to disintegrating. There's a thread in here somewhere about someone building a replacement.

[captainmcjedi]

Feb 24, 2014 17:08:41 GMT -5 dclambertt said:

Evidently these bushings are prone to disintegrating. There's a thread in here somewhere about someone building a replacement.

Looks like this is the thread:

msport97.proboards.com/thread/6793/4x4-lever-stuck

And this is how I'm spending my afternoon. 

[ES_97Sport]

Mar 3, 2014 16:38:34 GMT -5 captainmcjedi said:

Feb 24, 2014 17:08:41 GMT -5 dclambertt said:

Evidently these bushings are prone to disintegrating. There's a thread in here somewhere about someone building a replacement.

Looks like this is the thread:

msport97.proboards.com/thread/6793/4x4-lever-stuck

And this is how I'm spending my afternoon. 

I can't remember where I found the information. The Toy guys have a similar problem and there are a couple threads about using - and I can't remember what its called, of course GRRRR!!! - some very durable polysomething or other and machine a replacement ball.

It has to be a LITTLE flexible, so it shouldn't be made out of metal. Also, it needs to absorb vibration to some extent - or its going to sound like hell on the highway.

Anyway, the stuff they were using was machinable. I THINK I read about it on Pirate.

Edward

[captainmcjedi]

Mar 3, 2014 17:13:18 GMT -5 ES_97Sport said:

Mar 3, 2014 16:38:34 GMT -5 captainmcjedi said:

I can't remember where I found the information. The Toy guys have a similar problem and there are a couple threads about using - and I can't remember what its called, of course GRRRR!!! - some very durable polysomething or other and machine a replacement ball.

It has to be a LITTLE flexible, so it shouldn't be made out of metal. Also, it needs to absorb vibration to some extent - or its going to sound like hell on the highway.

Anyway, the stuff they were using was machinable. I THINK I read about it on Pirate.

Edward

Thanks Edward.

Hey in the meantime, I ran across this thread too:

msport97.proboards.com/thread/4598/4wd-shifter-bushing-failure?page=1&scrollTo=22128

He made one out of PVC, since the part was backordered, and has a couple of pics of his fabricated one. Also, one of the users in that thread mentioned that he called the dealership, and they said you could still operate without that bushing... that it basically kept the shifter from wobbleing around (just for a temporary deal-with-it fix till I can get a permanent fix). What's your thoughts on that?

Also found this too:

www.ebay.com.au/itm/4x4-4WD-Super-Select-Shifter-Fulcrum-Ball-Bush-Some-Mitsubishi-Montero-Sport-/181330226201?pt=AU_Car_Parts_Accessories&hash=item2a381fac19&_uhb=1

That looks like the part... pricey for a bushing, but cheaper than the entire shifter assembly.

[ES_97Sport]

Mar 4, 2014 14:25:37 GMT -5 captainmcjedi said:

...

Thanks Edward.

Hey in the meantime, I ran across this thread too:

msport97.proboards.com/thread/4598/4wd-shifter-bushing-failure?page=1&scrollTo=22128

He made one out of PVC, since the part was backordered, and has a couple of pics of his fabricated one. Also, one of the users in that thread mentioned that he called the dealership, and they said you could still operate without that bushing... that it basically kept the shifter from wobbleing around (just for a temporary deal-with-it fix till I can get a permanent fix). What's your thoughts on that?

Also found this too:

www.ebay.com.au/itm/4x4-4WD-Super-Select-Shifter-Fulcrum-Ball-Bush-Some-Mitsubishi-Montero-Sport-/181330226201?pt=AU_Car_Parts_Accessories&hash=item2a381fac19&_uhb=1

That looks like the part... pricey for a bushing, but cheaper than the entire shifter assembly.

No worries. I think I finally remembered - its Delrin.

Hmmm. If you can make it fit correctly, I don't see why it wouldn't work, but the question is more along the lines of how long will it last? Whatever the material is it has to be able to withstand heat - and our t-cases, do get hot - and the t-case fluid (and all the chemicals therein).

I don't know if PVC will hold up long term. Mechanical engineering is more my thing, not chemical engineering.

Ha! That's funny!!! I guess it depends on what your definition of 'operate' is. I've lost two transmission shifter balls and two or three t-case balls. The last transmission shifter ball went while we were out in Moab. Yes, it is possible to still shift if the ball just breaks up and the pieces fall out, but it's miserable. Especially if its the transmission shifter. But, it's difficult and not something you'd want to have to do for more than to limp home. That ball locates the shifter in the cup so it does a lot more than just 'keep the shifter from wobbling around'.

I have a pair of old shifters for both the transmission and transfer case. I kept them 'cause I'm still planning on coming up with a replacement for the ball, but I haven't delved into it much. Its been cheaper for me to replace the shifter assembly than to devote my time to a solution for the last couple years. Sigh.

That one on ebay might work. I'd get the dimensions first and compare them to an intact ball. It appears that you will need a hydraulic press. I did try to knock the pin out quite a while ago with a hammer and punch - that didn't work.

Yea, shifters are not cheap and they're getting hard to get, too. The last one had to come from Japan.

Edward

[mudrunner]

I know my old 4runner had a I shape at the end of the gear shifter not a ball. Not sure about t case though.

[dclambertt]

Yup, that's the thread I was referring to.

msport97.proboards.com/thread/4598/4wd-shifter-bushing-failure?page=1&scrollTo=22128

[captainmcjedi]

So I at least got a little time to post what I've done so far with my shifter. Hopefully this will be helpful to someone else that needs pics with their instructions (like I do)

First thing's first... take out that center console. Should come out in 3(ish) pieces. The screws are on the sides of the the console (near the front of the vehicle), in the cup holder, and in the console storage. You may not have to remove the entire assembly, but I didn't really know what I was dealing with, so I just took the whole thing out. I found a couple of decent exploded diagrams online to know what to expect:

Console:


Shifter:






You will have to take the handle off the gear shifter, but there's no need to take the shift handle off the AWD shifter; there are 4 screws that go in from underneath the leather boot and hold it on to the console... just get that middle section high enough to find those phillips screws. Remove those and the console will be free. Then remove the 6 bolts that hold the rubber boot on:




Once you get the rubber boot off, you can see the bolts that hold the shifter to a plate on top of the T-Case. I removed those first, but ended up having to take that entire plate off. As soon as I got the shifter loose, I could see the destroyed pivot ball underneath:



When you get the 3 nuts holding the shifter down, you should be able to lift it straight up. Here's the inside of the shifter where the pivot ball should be:



Here's a shot looking straight down into the T-Case. The 3 bolts that hold the shifter in place are just that; bolts. Not studs. So once you loosen the nuts they are likely to fall in the T-Case too. Like mine did   But I would've had to take that plate off anyway just to get all the pieces of the pivot ball out. There are 4 bolts to get that plate off:



See that small rod in the above pic that looks like a bent metal coat hanger inside the T-Case? When you get ready to re-assemble, make sure the shifter is on the DRIVER'S SIDE of that rod. It keeps tension on the shifter and holds it on the right piece in the T-Case.

Now for mine, I don't really use the 4WD much. So I did a quick/dirty/cheap fix: just removed the pivot ball and re-assembled. That way I could at least know it was in the 2H/AWD position. I will probably order this part, but just haven't had a chance to do it, and there's not a guarantee that it fits:

www.ebay.com.au/itm/4x4-4WD-Super-Select-Shifter-Fulcrum-Ball-Bush-Some-Mitsubishi-Montero-Sport-/181330226201?pt=AU_Car_Parts_Accessories&hash=item2a381fac19&_uhb=1

I need to do a little finer measuring and see if it's the right size. The only way for me to measure now is to piece the ball back together the best I can:



I have noticed that without the pivot ball, it shifts into 4H just fine. However, I can't find 4L at all. There's just too much play in the shifter. 

Anyway. More to come. Hope this helps someone out there.





** I realized I forgot to mention a step for the reassembly... make sure to use RTV sealent or the proper gaskets when putting your shifter back together. Otherwish you WILL be leaking t-case fluid.

Also, I am able to use 4L without the bushing. I found I had to push down on the shifter, then shift to 4L. Works like a charm.

[ES_97Sport]

Mar 24, 2014 13:55:17 GMT -5 captainmcjedi said:

So I at least got a little time to post what I've done so far with my shifter. Hopefully this will be helpful to someone else that needs pics with their instructions (like I do) ....

Nice! Thanks! I'm glad someone finally posted pics. Since I am apparently the only 5-speed driver left it doesn't do much good to post pics of that.

Edward

[greg409]

Captain, as I look at this(thank you)- I can't help but see a greased red poly bushing

luck,greg

P.S. - I'm going to do my '02 MS LTD soon

[mudrunner]

Awesome write up! I was looking at mine in a time crunch so I didn't get so far as to pull the shifter off. Didn't know how far I was going to have to dig.

Down side on taking my center console out is the front screw in the cup holder lost its head... so I have too pull the entire console out...