My '97 Sport just started giving me the code for the NSS. At first, it came and went, but now it stays on and won't go into OD. This is my 3rd Cherokee and I have become pretty good at general maintenance & repairs but this is the 1st time I feel trouble. I went to remove the bolt holding it in and it snapped off. This was after 40+ minutes of soaking with Pblaster. It didn't even seem hard but more like the darn bolt was made of zinc! So now I have a switch that is failing and a bolt snapped off. There is literally no room for drilling, etc.. I really hate to pull the motor just for a 40 minute NSS rebuild or swap. I am (assuming) that the switch itself isn't threaded so there "might" be a way to pry the switch off gently and then try and figure out how to remove the broken bolt.

Any ideas at all?

Thanks
Steve

 

Well crap, can't pry the switch loose for anything. Really in a pickle.

 

The rusted nut on center of NSS needs to also come off. Here are write-ups;
http://bc4x4.com/tech/2010/jeep-neut...ty-switch-nss/
https://www.cherokeeforum.com/f2/neu...1/#post1948879

 

Yep thanks, I have the write open in another tab and also watched some videos. I am still working the switch out as shown in the BC4x4 write up, but it won't budge. Likely the broken nut is pressing hard on the switch housing and of course grime and such not helping. Just taking my time and working it. Once I do get the switch removed, I have to deal with the sheared bolt. There is no room for the easy ways of removing a broken bolt.

 

Perhaps the second link I posted, about using wood shims in manner.

 

Thanks again. Getting shims in there is going to be tough, but I am not so bull-headed I won't try. Again, the fact that the bolt sheared is making it tough to get any separation at all.

 

After 2 days under the Jeep I am going to have to bring it in. I just don't have the tools and the fact that I sheared off the 12mm bolt head, that has to be dealt with also. What a drag.

 

My NSS broke trying to pry it off, but I had no choice, I tried everything. Once you get it off, you should have part of that broken bolt exposed where to you can spot weld a nut on it and get it off that way. Heat it first. If that doesn't work, you should be able to get a right angle drill in there, no?

 

I wonder how far a guy could drop the trans with say the fan, exhaust, and tranny mount loose or off. Boy, linkage also. Some guys have posted destroying their NSS chiseling it off, sounds better than a shop bill to me. As mentioned, you might have a stub of that broken bolt to work with. Sorry man, that sounds miserable! Get an estament in writing if you do "go in".....

 

Yep, just a little more working room would go a mile! Luckily it's just a weekender as the Wife has a new Renegade and I drive an F-150 4x4 for work.

 

I got the switch out. Rocked it back & forth with 2 screwdrivers and it finally started to wiggle. It was ruined in the process, but I have a new one in my hands. I still need to deal with the 1/2" of sheered bolt though. I'll see if I can find a good 'ol boy machine shop to get it out.

In the meantime, I bypassed the switch so I can drive it to a shop.

Thanks for the encouragement.

 

Can you get a vice-grips on the stub? I use that kind of stuff as an excuse to buy a new pair, now I have 4 different kinds. The small ones can be indispensable...They make a small needle-nose ya know.

 

I have 3 sets of vice grips. Only the larger, original type will grip the stub enough for any movement. Between heat and CRC Freeze Off, I got a little movement. Problem is, it is about 1-2mm at a time due to space. At this pace, it will take a thousand turns!

 

Drove the Cherokee around for a while with the switch jumpered and applying heat and penetrating oil a few times. Finally had a friend weld a nut to the broken bolt and she came right out. Took about 10 minutes to get the new switch on and all is well.

 

Supper! Somebody should make a female E-Z Out. Like a backwards die. Happy trails!