Transfer lever is too short?

Joined: 15 Apr 2004 Location: Out and about

Well ive finally got around to it and built the new transfer case for the 1KZ-TE conversion- Started with a G52 gear driven transfer case, added an Advance Adaptor R151F -> gear drive transfer case adaptor plate, Full Terrain Taimer bearing kit and 4.7:1 Trail Gear low range gears.

It all went together without a hitch- BUT after i bolted it to the back of the gearbox and tried to drop the transfer case shift lever in, its now too high to engage the transfer case forks! Crying or Very sad

What the hell do i do now?

Joined: 30 Jun 2004 Location: Perth

What you do is lengthen the shift lever by 16mm so it sits back in the forks. this is because of the adaptor plate making it sit in a diff place.

Use an old engine bolt cut the lever in the middle use the 16mm bolt make sure it is the shank part of the bolt not the thread its stronger taper both ends of it and weld it together. Or use a Grade 8 bolt if you can find anything else.

Make sure you lengthen the part below the ball that it sits in the base with. not the top of the lever incase you thought that.

Joined: 15 Apr 2004 Location: Out and about

Cheers for that! I went looking to see if someone made one aftermarket, but a quick look at the machining on the ball and knob bit made me realise that was NOT going to happen or be cheap!

I really need to go borrow my cousins mig welder... this is a bit beyond stick welding Embarassed