DIY Transfer Case Levers Mount Replacement Shaft

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Posted by Vaughn [] on Wednesday, June 03, 2020 at 15:53:27 :

My objective is to eliminate as much rattling of levers in the cab as possible. The TC levers are known for this as they wear the shaft and bushing when rattling side-to-side eventually laying against the slot sides of the cab transmission cover. It's difficult to get the right combination of washers to tighten them so I'm doing a different approach.

Using basic hand tools, I cut a 3/4, 5 inch grade 8 bolt cut to the length necessary and ground to the step down to fit the mount, I then welded it in place. The 3/4 bolt is .001 smaller than the shaft, so there is no concern there. I'll be using .010 stainless steel washers in between and on the sides of the levers to minimize wear. An extreme vibration lock washer will be used to allow adjustment of the tension on the levers, forward/backward movement, yet eliminate excessive clearance to prevent rattling and wear. There are 13 images, click the right arrow, the last picture has a coat of silver paint, and paint always makes anything look good.

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