The lower bolt broke when i was removing the nut from the shifter cable. Im removing the transmission to replace a broken flexplate, anyways, anyone know if this bolt can be replaced easily?

 

That's not a bolt, it's the manual shift rod. It goes all the way thru the trans and out the other side to operate the NSS. Changing it requires disassembly of the trans.

 

Got a scrap transmission you can steal parts from?

 

well that's a kick in the nuts for me... I'm not sure what I'm going to do about it as, no, I don't have a spare trans and have no idea how to replace it. Guess this job should have been left to a shop.

But I'm in it now - any other advice on replacement? CCken, this may be a dumb question but how much disassembly of the trans is required to fix it?

Any advice on getting out the other shifter linkage for the transfer case in the rear (other than don't break it)? I was pretty pissed when that guy broke so I just called it a day yesterday.. I'll be slowly screwing up my xj more today I guess

 

Go to Pacific Coast Manuals and download a service manual for your Jeep. Advertised as $7.95 but I hear they've upped it to $8.95 at checkout.


http://www.pacificcoastmanuals.com/j...e_manuals.html


There's a whole section in the Service Manual about the AW4 and the transfer case.


A must have for anyone maintaining their Jeep.

 

Too late now, but if you look at the end of the rod, sticking out of the nut, you'll see flats machined into the end of the rod. They are intended to be held with a wrench while unscrewing the nut.


Of course, lots of penetrating oil before attempting nut removal.


Sorry about twisting the blade....

 

Yea in hindsight, should have at least put some PB on it.. but I didn't see any rust - until it broke. A ton of corrosion and rust inside the nut. Also, didn't notice the flat parts at the end of the rod until the damage was done. It broke off with barely any torque.. thanks. I'll keep working on it.

 

This is what the repair/location for this rod (manual valve shaft) looks like correct?




Location of rod, correct?




Thanks in advance guys. This is just all new to me.. and like I said, I'm kinda into it now and up the creek with broken paddle.

 

ok, so ive been doing research in my area to find a couple jeeps being sold for parts.. Im considering swapping the trans for several reasons:

1. the cost to fix that rod will be expensive.
2. to fix the rod I will need to drain the fluid and (IMO) would compromise my high mileage trans to suffer many problems later.
3. I am currently without a 4w drivetrain... (long story) and could get one through the same parts vehicle.

I considered selling my xj, but i cant bring myself to do it. I love the thing. It is just starting to have a lot of heavy maintenance lately and i want to get it back to the best condition i can.

Any advice???

 

Pull the lever off, grind down the end of the rod smooth. Drill out for tap...maybe 5mm. Use short bolt and fender washer to hold the lever on temporarily until you decide what to do.


You're screwed anyway, might as well try.

Be careful to drill it straight and not go deeper than you need to, take your time tapping the hole, be easy when you tighten the bolt......you got one shot at it.


Edit:

If you need clearance, use floor jack under the xmember, unbolt xmember and lower the trans a couple of inches.......you won't damage anything but be careful and aware.

 

You're kidding, right?

 

No, I'm not kidding.

He could also JBWeld the lever on too.

I'm assuming by his post that he just needs to get by for a while as he's swapping to a 4WD trans anyway.



When one's *** is in a sling one does what one must do.


Its only a lever.

 

I had mine break a few years back. I originally just jb welded it and that worked out great, but when I was redoing my trans seals I decided just to put a new rod in and now it's as good as new.

 

What year / condition is this vehicle in? It sounds like with the broken flex plate and now jacked up transmission it's probably not worth a whole lot. Might be farther ahead to just cut your losses right now and buy something else.

 

Thanks. This crossed my mind..