I have been toying with the idea of spending a couple hundred bucks for the Advanced Adapters transfer case cable kit, which eliminates the "lost or broken" plastic clip which holds the cable to the arm. I looked at the hookup yesterday, as good as you can see it without dropping the driveline and hub, and was wondering if anyone out there has ever seen this part close up, and if so, can you tell me if it is just an arm coming off the transfer case with a rod that the heim joint goes onto and the clip holds it there? If so, I was thinking about taking off the arm, fabing a new arm with a rod to go through the heim joint with a hole in it and put a cotter pin in. Or the other option would be to fab an arm with a hole in it to put a bolt and nut through the heim joint and connecting the two.
Any comments would be appreciated.

 

Without the plastic bushing, the hole in the cable end is much too big for the pin on the lever. You would have to make a bushing to fill the hole.

There are several threads on how to fab up a new attachment without having to replace the entire cable and lever.
One way is to cut off the end of the plastic bushing. That way it will fill the void between the cable end and the pin, and install an "E" ring on the pin.
But, you still have plastic parts involved.
The Advanced Adapters solution will be the last time you have to deal with the entire linkage.

Here is a closeup shot: