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02 F350 7.3 4wd with the manual transfer case 271 swapped in. Recently my shifter in floor came loose, bad timing with this snow storm. I climbed under the truck today and it appears the nipple has snapped off. I have attached a stock pic of the part that's broken. I cannot find a part number for this part and it's driving me crazy. I'm trying not to drop the piece off and ghetto rig some other setup through that lever to my linkage. Any help would be greatly appreciated!
In my experience the stud snaps off from force when the selector shuttle/gear inside on the main shaft is sticky and the handle is slammed back and forth to try and get it into 4H, orrrr when someone tried to force it into 4L without the trans being in neutral. Why would the sliding gear be sticky? The transfer case fluid is either faulty from lack of maintenance (should be changed every 30k) or the oil pump is faulty. I'd recommend changing the fluid with Mercon V. As far as the linkage, take it off, grind off the nipple stud, and drill it to fit a 5/8 OD x 3/8 long shoulder bolt right thru the shifter linkage into the selector linkage. If you can snap off the shoulder bolt you're a He Man, you'd bend the linkage before that bolt bends or breaks.
In my experience the stud snaps off from force when the selector shuttle/gear inside on the main shaft is sticky and the handle is slammed back and forth to try and get it into 4H, orrrr when someone tried to force it into 4L without the trans being in neutral. Why would the sliding gear be sticky? The transfer case fluid is either faulty from lack of maintenance (should be changed every 30k) or the oil pump is faulty. I'd recommend changing the fluid with Mercon V. As far as the linkage, take it off, grind off the nipple stud, and drill it to fit a 5/8 OD x 3/8 long shoulder bolt right thru the shifter linkage into the selector linkage. If you can snap off the shoulder bolt you're a He Man, you'd bend the linkage before that bolt bends or breaks.
This is just an old Tcase kind of break. Fluid is good, it wasn't abused either when shifting. I know how to use it. Lol! It's most likely because of the cold weather. Or it could have been "smacked" by the driveshaft when I tried to use it the other day and found I was missing 3 of 4 bolts to connect it to the t-case. The front driveshaft. Looks like I almsot fell prey to the driveshaft thievery that has been been striking my area the last few months. I got it put back on and it works fine, just can't get the linkage to stay on. I'll just have to rig it, I'd much prefer to just swap parts though. Lol!
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