4wd Shifter Bushing Failure

[colosport]

I'm in the process of having my 02 Sport's transfer case resealed and new output shaft seals installed.

Called the shop doing the work - not a dealer - they indicated that everything was completed - -a little under $1000. However they said that the 4WD shifter had a nylon bushing that was shot and they need to replace it before they could finish the job.

They called the dealer in Colo Springs and Denver and was told the part was on a national backorder and would not be available until mid-Jan 08. The base part number they gave me was 30600A.

Has anyone had a similar problem with their 4wd shifter. The fact that there is a national backorder makes me wonder if this is a bigger problem.

[tof95]

Well yes my 00 sport had the same problem!! I ended up getting a rebuilt T-case and come to find out how the problem occured is deeper than thought, That dran flshing 4wd light was because the vaccum switch unit on the fender had gone bad not letting the the front axle unlock causing you to drive while still locked I had logged meny Miles with this problem. Now I am pay for it.

After 1.5 months and no sport to drive the mech is still stummed because after that unit was replaced the front axle is not unlocking. so maybe someone can help me tell the mech what to check!?!?!?!?!

[skoze]

I don't know if this is similar or not, but when I would put my 04 Sport in 4 high, the light would continue blinking, then the anti-lock brake light would go on. This happened several times, at leats three or four. I would take it in and they would replace the switch on the case. Also, I would contuinue to put it into 4WD in the off months to keep it lubed up, but it still would do this.

After the last time, I complained, espcially since the warranty is about to expire, and I wanted it fixed right. They had it for about two or three weeks, but were also doing other things. When I got it back, they siad they had to go in and replace a few items, and fix something else, as it was gumming up and jamming it up. I don't know exactly what they did, but it has worked fine ever since.

I'll look at my paperwork and see if it explains it better than I just did.

[colosport]

I went by the dealer and got the part number for the linkage assembly and they did not have a diagram which actually shows the bushing so no idea what part number it is. The actual assembly number is MR 953732 and looks like I have to buy the entire assembly approx $300 in order to get one bushing.

[Eonknight]

I have the same problem. Couldn't shift from AWD to 4WD. Took the shifter appart and, lo and behold, My bushing was in little pieces!

Note that my bushing was completely destroyed, so it doesn't appear in the picture. The whole "bell" assembly (w/bushing) is held by a spring-loaded cup and a transverse pin that seems press-fitted. On mine, this pin is off-center, which I believe led to the malfunction.

I need help here : Does anyone know if there is a bulletin on this issue or if the bushing CAN be replaced without getting the complete assembly? Everywhere I turn, people tell me it is a common failure and the fact that the parts are B.O. seems to confirm it.

Joel, if you could shed a little light on the subject for us, it would be very much appreciated!

[Eonknight]

Update:

I removed the clip holding the spring, the plastic cup and the "bell" in place so I could get a closer look.

As suspected, the pin is press-fitted and is completely off-center. There is a mark on the "long" end that suggests that considerable force was applied by the press, without much success.

Again, all input is appreciated.

[Eonknight]

Well, this is getting long and I need the truck functional, so I decided to try to make another bushing from PVC, with the counsel and help of my gearhead of a father-in-law. Will keep you informed and will put up pics if/when done.

Wish me luck!

[frogman27]

Hi there

Would you like to see if I can get one in Australia for you? Just give me all your vehicle specs, including V.I.N number and I will chase it up. I live in Australia and own a 2003 Challenger, Id be glad to help out. I need a little help from the US as well.

[Eonknight]

Thanks, but I got the problem solved. Me and my father-in-law, we made a new bushing from PVC pipe.





All it took was some careful measuring and a little creative knife work, and my selector now works like new. Will still write to Mitsubishi Canada to document this and take advantage of any future recall/TSB...

What is it you need, Frogman?

[frogman27]

I'm Chasing (my car being R/H Drive) a R/H/R flare gaurd. Any chance of seeing if one might be available in the US? over here they want $450 australian, rip off.

[fist]

Jan 15, 2008 21:09:40 GMT -5 Eonknight said:

Thanks, but I got the problem solved. Me and my father-in-law, we made a new bushing from PVC pipe.





All it took was some careful measuring and a little creative knife work, and my selector now works like new. Will still write to Mitsubishi Canada to document this and take advantage of any future recall/TSB...

What is it you need, Frogman?

Hi, I hate to bring this old thread back from the dead, but I did searching on this site and many others and this is the exact problem I am having.

The pictures of what the above person made are no longer viewable. Does anyone happen to have them saved anywhere? If not, does anyone else happen to have a fix for this besides buying the entire shift assembley? I can't see spending that much money just to buy a plastic bushing.

My biggest problem here is that my 2001 Montero Sport is not only flashing the light, but it seems to be going in and out of 4wd a lot on it's own. When I took aprt the shift assembley to get a better idea of what was going on with it, I noticed that the bushing had broken up into a lot of pieces and was wedged all under the spring. I assumed this was the problem so I cleaned it out, put it all back together and still had the same problem. Does anyone know of a fix for this bushing problem?

[wrkrbee]

I had this same problem, except my bushing was more like a red rubber ball. I called the dealership looking for it, and was told they were out and not sure when they were going to get it back in.

I asked the dealership what the "bushing" was for and was told only to dampen the shifter from shaking while underway and that it won't do any damage without it.

I thought that was a little suspicious, but since I looked around at junkyards and nothing, I really didn't have a choice.

I went ahead and put it all back together and the vehicle is fine and shfits into 4H and 4L fine.

[Eonknight]

A little late, I know, but here are the pics nonetheless:

[bdmontero]

Good work guys!! Size and length for other people to know?

[Eonknight]

Thanks, bdMontero. Unfortunately, it's been too long; I don't remember. But my bakelite ball was completely disintegrated, so we had to extrapolate by measuring the inside of the housing. From what I recall, it's not too hard to figure out.