how to: 5 minute repair for broken 4wd lever stud

civtec350

i broke my stud while rebuilding my transfer case the other day





i used a piece of shelving and drilled 2 holes in it, and notched it for the speed sensor.





i used the existing hole for the speed sensor hold down to secure the strap into place.



it works great with no play. if i ever have the need to move the lever into 2wd i would have to take the bolt out and make a longer strap if i wanted it to be clamped down.

greenteagod

Super boogan! No easy outs available? That's definitely one way to sort it though, guess there must have been a need for a quick fix I take it?

bam-bam

gtg, there's a lot more involved there than just an easy-out. You'd have to disassemble the whole transfer case to remove that shift shaft to even start trying to drill the bolt. Add to that the fact that the bolt is seized in the aluminum case hard enough that the bolt sheared? I think this is a decent solution.

klum

some guy just had a post about the same problem and sounded hopeless good use of random garage parts !

LowFlyin'

My fix was to drill a new hole in the case. Can't wait to put the ZC in so I can finally fix it right.

greenteagod

Cool, wasn't nay saying by any means. I just didn't know what all that went to since I'm still rockin' FWD. The only time I've dealt with a sheared bolt like that has been on vespa cases and we were able to torch the thing enough to get the stud out. Either way, I'm all about the DIY fix if it gets the job done.

civtec350

i do remember someone posting about this problem, so i figured i would show a simple/basic way to fix it, and im happy with how it came out.