I started a thread the other day asking if anyone had found a way to make the 4X4 shift stop rattling at highway speed. Thanks to those who responded! I came up with an easy way to fix it other than sticking a glove over the shifter. Here's what I did:
1. I took the whole shifter linkage off the truck to make it easier to work on. First take off the shift **** and jamb nut, then disconnect the bent dowl/cotter pin from the other end of the shifter (under truck.) There are three bolts that hold the linkage bracket to the trans. Take them out and the linkage is all yours.
2. This is what the shifter/bracket looks like before any modification
My first idea was to simply replace the bushing in the shifter to get rid of the slack and the rattle. I found some flanged bushings at the hardware store that fit nicely. The ID is 3/4", and the OD is 7/8". I drove them in while driving out the old bushing.
3. While looking at the bracket that the shifter pivots on, I got an idea. instead of using a cotter pin to hold the shifter on loosly, I drilled a hole in the pivot...
stuck a piece of threaded rod in the hole and welded it in place.
Then I stuck the shifter back on the bracket, added some washers, and put a lock nut on the piece of threaded rod.
Now to keep the shifter TIGHTLY on the pivot, I tightened the lock nut down until shifter was snug, but easy enough to move.
4. Took her out for a test drive, and NO MORE RATTLE!!! worked perfectly, and if the rattle ever comes back, all I have to do is tighten up a little on the lock nut.
