I KNOW I saw a good writeup with pics at one time. I searched...got nuthin. I want to do the circlips and scrap the cheesy breakable bushings under controlled conditions instead of dealing with it trailside in the mud!

 

My bushing went to crap as well, just picked up one at the stealership. If there is a good thread showing an upgrade I'd like to find it as well.

 

Try these threads. I found these by doing a Google search for "site:jk-forum.com 68064273AA". That's the part number for the cheap plastic bushing that's causing all the grief.

transfer case stuck in neutral
JK Automatic Transmission Linkage Bushing Fix
4 Wheel Drive Cable Breaks
Broken transfer case link
Another mans shift linkage repair
Transfer Case Shifter Cable - Report to Jeep & NHTSA

 

Thanks mvymr!

The first one "stuck in neutral" is the one I remembered.

 

Just reviewed that one. My bushing broke today on the trail!

 

It's like a $0.35 part....I carry a few in the glove box!

 

I got some metal bushings from the hardware store and replaced the plastic ones with that and a small hitch pin. Has worked pretty well so far. The write up is one of the links above.....

 

I did something very similar. I drilled out the black linkage eye to 1/2" with a step bit. Used a 1/2" screw cap and cut the tip off (used as a new bushing). Then used a cotter pin to hold everything together. There is a groove on the nipple that accepted it perfectly.