For those that are going to experience the old cable falling off the transfer case lever try this mod as shown. Pic not very good but I ground the back of the existing pin flush (drill won't touch it) and used a 1/4" pin punch to wrap it out. Drill the hole out to 5/16" and use a 5/16NF bolt that has a smooth shank and thread.. Extend the shank out the opposite side the cable clevis goes by 1/8-1/4" to get a weld attachment. Weld it. You need about 5/8" smooth shank on the other side and then a 5/16 fender washer and Nylock nut with about 2 threads sticking out of the nut. Bottom out the nut on the threads for double lock feature. Washer stops the clevis coming off even if it falls apart. Bit tight to get in there but it is doable. Lever bolt has factory blu loctite so replace at assembly. That stock design is pathetic seeing as it is on a new 60-65K$ vehicle. This is what I call a 1000 year fix. Imagine the vehicle is only as good as its weakest part and it did fail 1 week ago in the bush.

 

I imagine you must’ve been pretty ticked to go through all that trouble! I had it bust on me a few months ago but luckily I was in the driveway.

mine lasted 10 years and I was able to replace them by getting my elf fingers up in there so I just bought a few extras in case it happens again. Nice work on the mod

 

Wasn't too bad. It broke straddling a dry puddle on a level road so lots of working room to wire it up. Had to wait for exhaust to cool down. This new fix will never let go now.