Transfer Case Shifter Cable - Report to Jeep & NHTSA
10-15-2011, 10:08 AM
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Transfer Case Shifter Cable - Report to Jeep & NHTSA
When we were out on the AZ desert backroads in the ‘08 Ruby (8,000 miles on the OD), we experienced the transfer case shifter cable problem (thank you all for posting this forum). I had shifted from 4lo to 2hi after clearing the last bad stretch of rocky-road incline, and it happened ... lucy-goosy TC shifter (later learned it was the shift cable at the TC side). Fortunately it did complete the shift to 2hi before breaking, and we took it slow home in 2wd over a few small rock gardens and grades. It’s out of the 3-yr factory warranty, but luckily bought a Ford extended warranty. Short story is Obama closed down the Chevy/GM and the Jeep/Chrysler dealers here, and only Ford remains, and we has already bought a Suburban and a Jeep! Nearest Jeep dealer is 50 miles. Good news though ... the Ford dealer is getting back his Jeep dealership in 30 days. The Ford dealer replaced the entire cable with Mopar cable shifter assembly Part # 52060462AG (not just the bushings) ... part cost $20-30; labor 2+ hours @ $95/hr (billed to Ford). I read on another forum about a Mopar replacement bushing and clip (part #’s 68064273AA & 68018106AA). Haven’t seen pix, so don’t know how the bushing could be “pressed” back into the cable ends, let alone being able to do a field service at either end of the cable? Has anyone seen these parts?
I had also read on another forum that Jeep was re-engineering the cable with metal bushings, but they haven’t done it yet, because my new Mopar replacement cable is still plastic bushings. I wrote Jeep and asked when they will start using metal parts (http://www.jeep.com/webselfservice/s...eep&category=U). Their response is as follows (there will be no recall unless it becomes a “safety” issue):
Thank you for contacting the Jeep Customer Assistance Center in regards to your 2008 Jeep Wrangler.
We appreciate the time and effort you took to tell us of your dissatisfaction in our product. Comments like yours are one way to learn of problems that develop and the improvements desired. We have documented your comments and provide them to the product development team for review.
Chrysler Group has made tremendous gains in customer satisfaction and vehicle quality and we are dismayed to learn that your expectations have not been met. Please accept our apology for the problems you have experienced.
Once a determination has been made by Chrysler Group LLC that a safety recall is necessary to correct a problem with one of our products, a report is sent to the National Highway Traffic Safety Administration (NHTSA) to advise them of the issue. Since this typically occurs in the early stages of the overall recall process, the vehicles involved and the repair procedure have not been finalized. Further, the necessary repair parts need to be manufactured and distributed to our Dealers. When all of this is accomplished, the recall is "launched". At that time, involved vehicles are loaded into the computer and our Dealers and customers are sent recall notification letters.
The involved vehicle information for a recall is not available until the recall is launched. Therefore, the information you are seeking is not yet available. If your vehicle is involved in a recall you will be notified by U.S. mail. If the number of recalled vehicles is substantial, often a phased launch is conducted and notices are sent out over a period of time.
If you are experiencing any problems with an issue you feel may be related to this recall, we would certainly recommend that you contact your local dealer to arrange an appointment so that they can inspect the vehicle and determine the appropriate course of action.
Thank you for your email inquiry.
Sincerely,
Crystal
Customer Service Representative
Jeep Customer Assistance Center
For any future communications related to this email, please refer to the
following information:
REFERENCE NUMBER: 21457643
EMAIL CASE NUMBER: 2632921
REPLY LINK: http://www.chrysler.com/wccs/brand_f...201V27095L0KM&
Original Message Follows:
------------------------
US Customer Service - Jeep Brand Site
Brief Description: Transfer Case Shifter Cable
Comments: When is Jeep going to address the constant and recurring problem with the plastic parts (bushings, clips) that disintegrate on the TC shifter cable. I understand that this has been going on for a few years! It's a major problem when out in the middle of nowhere and it freakin' breaks.
Well, let’s make it a safety issue by bombarding both Jeep and the NHTSA with consumer complaints ...
https://www-odi.nhtsa.dot.gov/Vehicl...nt/index.xhtml
After filling in the VIN, mileage, etc., here is what I filed with the NHTSA (character space is limited, so I had to shorten it):
Shifting the 4-wheel drive transfer case (TC) from 2hi to 4hi or 4low (or in reverse order) can cause the transfer case shifting cable (TCSC) (Mopar Part 52060462AG) to fail and become disconnected from either the TC or the shift lever in the cab (or both). The part’s plastic components are inherently too weak to withstand normal use. Safety risks which can arise upon component failure, if the vehicle owner and their family (children) are at a location and/or terrain where the vehicle is designed/marketed for travel (whether by recreation or necessity), and the location/terrain is: (i) subject to inclement weather (e.g. snow, ice, flooding, extreme heat); or (ii) on an extreme incline which is unsafe to negotiate without 4WD; or (iii) any circumstance which requires 4WD to navigate to a safe location; or (iv) the TCSC fails when the TC becomes stuck in the neutral position while shifting, and is unable to escape impending harm (flash flood) ... there is obvious risk to life/safety. The owner has a right to rely on the components and reasonable safety performance for which the product is designed/marketed. Jeep is aware of the issue, and the manual fails to cite this as a possible catastrophic event, leaving the unsuspecting owner at a loss in an emergency situation. It is not reasonable for this component to fail within a few thousand miles as reported by Jeep owners. Advance Adapters (www.advanceadapters.com) manufactures a TCSC which meets the criteria (Product# 715596) required for this component. There is no reason that Jeep cannot do the same and/or contract with Advance Adaptors to supply the part to Jeep owners. We urge NHTSA’s investigation of this safety defect and Jeep will redesign the defective part and issue a recall for affected vehicles on which the part was installed as OEM and to extend the warranty to replacement for life of the vehicle.
Checking the NHTSA website for complaints, I could find no complaints on this issue on the ‘08. http://www-odi.nhtsa.dot.gov/complaints/index.cfm
I had also read on another forum that Jeep was re-engineering the cable with metal bushings, but they haven’t done it yet, because my new Mopar replacement cable is still plastic bushings. I wrote Jeep and asked when they will start using metal parts (http://www.jeep.com/webselfservice/s...eep&category=U). Their response is as follows (there will be no recall unless it becomes a “safety” issue):
Thank you for contacting the Jeep Customer Assistance Center in regards to your 2008 Jeep Wrangler.
We appreciate the time and effort you took to tell us of your dissatisfaction in our product. Comments like yours are one way to learn of problems that develop and the improvements desired. We have documented your comments and provide them to the product development team for review.
Chrysler Group has made tremendous gains in customer satisfaction and vehicle quality and we are dismayed to learn that your expectations have not been met. Please accept our apology for the problems you have experienced.
Once a determination has been made by Chrysler Group LLC that a safety recall is necessary to correct a problem with one of our products, a report is sent to the National Highway Traffic Safety Administration (NHTSA) to advise them of the issue. Since this typically occurs in the early stages of the overall recall process, the vehicles involved and the repair procedure have not been finalized. Further, the necessary repair parts need to be manufactured and distributed to our Dealers. When all of this is accomplished, the recall is "launched". At that time, involved vehicles are loaded into the computer and our Dealers and customers are sent recall notification letters.
The involved vehicle information for a recall is not available until the recall is launched. Therefore, the information you are seeking is not yet available. If your vehicle is involved in a recall you will be notified by U.S. mail. If the number of recalled vehicles is substantial, often a phased launch is conducted and notices are sent out over a period of time.
If you are experiencing any problems with an issue you feel may be related to this recall, we would certainly recommend that you contact your local dealer to arrange an appointment so that they can inspect the vehicle and determine the appropriate course of action.
Thank you for your email inquiry.
Sincerely,
Crystal
Customer Service Representative
Jeep Customer Assistance Center
For any future communications related to this email, please refer to the
following information:
REFERENCE NUMBER: 21457643
EMAIL CASE NUMBER: 2632921
REPLY LINK: http://www.chrysler.com/wccs/brand_f...201V27095L0KM&
Original Message Follows:
------------------------
US Customer Service - Jeep Brand Site
Brief Description: Transfer Case Shifter Cable
Comments: When is Jeep going to address the constant and recurring problem with the plastic parts (bushings, clips) that disintegrate on the TC shifter cable. I understand that this has been going on for a few years! It's a major problem when out in the middle of nowhere and it freakin' breaks.
Well, let’s make it a safety issue by bombarding both Jeep and the NHTSA with consumer complaints ...
https://www-odi.nhtsa.dot.gov/Vehicl...nt/index.xhtml
After filling in the VIN, mileage, etc., here is what I filed with the NHTSA (character space is limited, so I had to shorten it):
Shifting the 4-wheel drive transfer case (TC) from 2hi to 4hi or 4low (or in reverse order) can cause the transfer case shifting cable (TCSC) (Mopar Part 52060462AG) to fail and become disconnected from either the TC or the shift lever in the cab (or both). The part’s plastic components are inherently too weak to withstand normal use. Safety risks which can arise upon component failure, if the vehicle owner and their family (children) are at a location and/or terrain where the vehicle is designed/marketed for travel (whether by recreation or necessity), and the location/terrain is: (i) subject to inclement weather (e.g. snow, ice, flooding, extreme heat); or (ii) on an extreme incline which is unsafe to negotiate without 4WD; or (iii) any circumstance which requires 4WD to navigate to a safe location; or (iv) the TCSC fails when the TC becomes stuck in the neutral position while shifting, and is unable to escape impending harm (flash flood) ... there is obvious risk to life/safety. The owner has a right to rely on the components and reasonable safety performance for which the product is designed/marketed. Jeep is aware of the issue, and the manual fails to cite this as a possible catastrophic event, leaving the unsuspecting owner at a loss in an emergency situation. It is not reasonable for this component to fail within a few thousand miles as reported by Jeep owners. Advance Adapters (www.advanceadapters.com) manufactures a TCSC which meets the criteria (Product# 715596) required for this component. There is no reason that Jeep cannot do the same and/or contract with Advance Adaptors to supply the part to Jeep owners. We urge NHTSA’s investigation of this safety defect and Jeep will redesign the defective part and issue a recall for affected vehicles on which the part was installed as OEM and to extend the warranty to replacement for life of the vehicle.
Checking the NHTSA website for complaints, I could find no complaints on this issue on the ‘08. http://www-odi.nhtsa.dot.gov/complaints/index.cfm
10-15-2011, 12:46 PM
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I really like the idea, but I don't believe NTSB really cares. After all they didn't find the transmission problem recall worthy, nor I believe the gas tank overflow issue. I would like to get the transfer cable issue fixed but I just don't have much faith. I will however send a report to the NTSB.
10-15-2011, 01:19 PM
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Gas Tank & Tranny
Thanx Hillmonkey. We never had a problem with the gas tank filler, but we did receive a lifetime warranty on it. Also, the tranny cooler idiot light was installed to supposedly let us know if there is an overheating issue. Seems like a tranny fluid cooler would be better if there is an issue with tranny overheating. Never had a problem with any overheating (yet). What really irks is they test these things on the AZ Chrysler proving grounds! And even when consumers have problems, they rarely fix it in the next model years. It's a numbers game and requires a substantial number of injuries or deaths before anything happens (Pinto & Toyota). Regarding NHTSA, I note that the overwhelming number of complaints were related to the gas filler. Gas spilling all over got their attention. I don't know, but if enough complaints are logged in, and something bad happens, at least my estate attorneys will have something to hang my hat on, and Jeep can't claim innocence. TIC
10-15-2011, 02:16 PM
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Yes...I agree with the above posts...just a numbers game and don't expect anything from Jeep. Definitely, failures should have been noted in the lifetime thermal cycles at AZ Proving Grounds.
I had the same issue a year ago. I was at Silver Lake, MI...I just came down a hill and was shifting to 4hi and head back to the camp site. We'll low and behold...the 4wheel drive shifter goes limp (loose and shifts freely). Checked to see if anything was leaking outside/under the JK...nothing. Turned the engine off then on, to see if I had any warning lights on...nothing. Since I was still in 4lo with no problems...I decided to limped back a mile, or more to the camp site doing 10mph on a 25 zone. After letting the engine and trans cool down...looked under the console (where the shifter cable attaches) and found no issue...cable was still attached to the lever with the plastic piece. Next was looking at the trans lever attachment...bingo, problem found. The plastic piece had deteriorated (lasted 2 years for me)...looks like the part could not handle the heat and cold cycles of the environment, and transfer case (gets pretty toasty...I didn't learn when I arrived at the camp-site.). My buddies just told me to place the trans cable loop (without the plastic piece) on to the lever and shift to 2hi...It worked. I was able to drive back home on 2hi without any problems.
Yes, these bushings are available (not sure about the clip part number and where its used), and you don't need to buy the whole cable assembly just the bushing itself (pretty pricey for the cable assembly). Very easy to press the bushing into the cable loop end.
After my 'event' at Silver Lake, I went to the dealership and purchased 20 bushings...pretty cheap part. Part is below.
Short term: I have 13 of these bushing parts on hand at home...5 inside the JK at all times.
Long term: Rebuild both ends of trans shift cable with Stainless Steel External Retaining Ring, Aluminum Shaft Collar, and Stainless Steel Washers. In addition, I'll use the current bushing and trim this as needed. I'll start this next spring...I have all the parts since last year, but I've just been lazy to start it. I'll document as much as I can.
If you need info sooner, there maybe other post with fixes on this. Be aware, zip ties will not work!!
I had the same issue a year ago. I was at Silver Lake, MI...I just came down a hill and was shifting to 4hi and head back to the camp site. We'll low and behold...the 4wheel drive shifter goes limp (loose and shifts freely). Checked to see if anything was leaking outside/under the JK...nothing. Turned the engine off then on, to see if I had any warning lights on...nothing. Since I was still in 4lo with no problems...I decided to limped back a mile, or more to the camp site doing 10mph on a 25 zone. After letting the engine and trans cool down...looked under the console (where the shifter cable attaches) and found no issue...cable was still attached to the lever with the plastic piece. Next was looking at the trans lever attachment...bingo, problem found. The plastic piece had deteriorated (lasted 2 years for me)...looks like the part could not handle the heat and cold cycles of the environment, and transfer case (gets pretty toasty...I didn't learn when I arrived at the camp-site.). My buddies just told me to place the trans cable loop (without the plastic piece) on to the lever and shift to 2hi...It worked. I was able to drive back home on 2hi without any problems.
Yes, these bushings are available (not sure about the clip part number and where its used), and you don't need to buy the whole cable assembly just the bushing itself (pretty pricey for the cable assembly). Very easy to press the bushing into the cable loop end.
After my 'event' at Silver Lake, I went to the dealership and purchased 20 bushings...pretty cheap part. Part is below.
Short term: I have 13 of these bushing parts on hand at home...5 inside the JK at all times.
Long term: Rebuild both ends of trans shift cable with Stainless Steel External Retaining Ring, Aluminum Shaft Collar, and Stainless Steel Washers. In addition, I'll use the current bushing and trim this as needed. I'll start this next spring...I have all the parts since last year, but I've just been lazy to start it. I'll document as much as I can.
If you need info sooner, there maybe other post with fixes on this. Be aware, zip ties will not work!!
Last edited by mscedro2; 10-15-2011 at 02:33 PM.
10-15-2011, 03:24 PM
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Get Over It - One end connects at the transfer case and one end connects at the console shifter. Get under the vehicle on the driver’s side and with a flashlight look at the transfer case side. The cable connects to a rod located on the driver’s side of the transfer case, but it is obscured by the crossmember plate. Have someone in the cab move the lever through the positions. If you can see the cable moving and it is not attached to the TC rod, then get hold of the cable end and slip it back on to the TC rod (warning exhaust pipes are hot ... wait until it cools down). This will allow you to shift into 2hi if you need to drive it somewhere for repair. There is a hole in the TC rod that I believe you can insert a hitch pin (R-clip) to keep the cable end from slipping off again until a repair / replacement can be made (forum correct me if I’m wrong on this). If the cable is still attached to the TC rod, then the problem is at the console shift lever, which I understand is a bear to remove.
SargeW has writeups on modifying the cable ends with metal bushings and also how to remove the console at ... https://www.jk-forum.com/forums/show...linkage-repair
If the problem is at the shifter end and you need to engage 2hi, Sarge says it is possible to move the rod at the TC by using channel locks.
SargeW has writeups on modifying the cable ends with metal bushings and also how to remove the console at ... https://www.jk-forum.com/forums/show...linkage-repair
If the problem is at the shifter end and you need to engage 2hi, Sarge says it is possible to move the rod at the TC by using channel locks.
10-15-2011, 03:27 PM
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Looks like usgroupie beat me too it.
Last edited by mscedro2; 10-15-2011 at 03:35 PM. Reason: usgroupie posted an update first
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10-16-2011, 06:25 AM
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Ok. I found it. It is at the shifter end in the console. I was able to lift console enough to put end on and shift back into 2wd. I can't get the shifter knob off so that I can remove the console. Any tips? I would like to fix this myself.
10-16-2011, 06:35 AM
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https://www.jk-forum.com/showthread.p...linkage-repair
Read the next to the last post on the first page 5/12/2011 8:45pm ... which begins "I didn't take pics of the console disassembly, but I did make some notes."
Also, the first post on that page Sarge tells how he modified the bushings.