05-15 2wd to 4wd conversion guide (for dummies)

Did you do a good job, sealing the floor after putting the shifter through it ? the shifter for the manual transfer case gets oil on it at least mine does from time to time so that might be what you’re smelling if you took the shifter out, you could see right into the gears and see the oil in there so that’s probably where the smell is coming from. I think I smell mine from time to time to, my floor isn’t sealed perfectly so that’s probably what you’re getting the smell of now for the quarter inch line coming off of the actuator. I just ran mine up into the engine bay with the breather tube coming out and I tied it to the one that’s coming off the clamshell I don’t know if that’s the one you’re talking about

 

Look on the side of the plastic actuator motor housing. There should be a nipple there for the other hose. Mine broke off when I installed the front diff so I drilled out the hole and jb welded in an aluminum one. I sealed the transfer case hole with sticky sound deadening material (Home Depot dynamat)and laid AC duct tape on top. Did you add a breather to the transfer case?

 

I am certain this on both topics is whats happening.. I spent some time looking around and pulling shit apart. My patch job on the tunnel is decent but not great! Used soe sound deadener to wrap around the whole inside and out. lol
We got the same idea with two two tubes in question, both together and routed into the engine bay.

 

Yeah i ditched the metal bracket after it gave us hell installing the clamshell. Hooked up a hose direct to them both and ran them into the engine bay. So looks like i'll leave if for now and figure the boot and tunnel seal.

 

Thanks for the reply, If i find anything funky or worth sharing i'll reach out

 

Thanks for all the information. I’m almost done with my conversion.

 

Nice ,another converted truck. ShOuLd HaVe SoLd AnD BoUgHt A 4x4.

JK thats awesome man welcome to the club.

 

Welcome to the club! You'll be soo happy you made the swap! Nice work, Enjoy the possibilities

 

Getting close. Don’t mind my ugly welding, I’m a mechanic not a welder.

 

Add switch

 

Cool but that Bird Sh*t weld wont hold anything, Sorry to offend, Maybe try more voltage, and hold the trigger a little longer, as you are holding the trigger write a cursive "e"..., loop, loop, and so on. Make sure your materials are clean. Thanks for your contribution, here maybe next weekend I will start my conversion.

 

already broke off, going to reweld it better tomorrow. Our power at the shop doesn’t seem to hold voltage well. So we don’t weld much here.

 

Hell yeah dude! Welcome to the club.

 

Id get someone else that can weld to weld it. Im saying this because when i did mine at the time wasn't that knowledgeable on welding. I had a flux welder and mine eventually broke. I was 450 miles from home stuck in neutral in a mud pit when it happened....

 

If you want it stronger drill a hole in the flat the size of the shifter shaft, slide the shaft through the hole slightly before you weld it, then weld top and bottom.

 

Once I get the shifter in place and make adjustments, I’m going to drill a second hole to lock the shifter plate in place. I didn’t want to weld it just in case I need to take it apart in the future. Only thing is I think this shifter might be too thick, might have to shave it down.

 

Scrap the old design, made a new one. The shifter was too short and stubby and not extended out far enough that it would hit the shifter cover going into 4 high. I extended the metal shifter plate out longer and left room for adjustment just incase and needed to drill and rethread it.

I had a worn strut that looked like it could be useful for a shifter.

To my surprise the strut rod has the same thread size as the shift knob/oem shifter. I’m going to shorten Rod about an inch or so and rethread it since it’s slightly too tall. The bottom of the Rod was actually threaded already so I just drilled and tap the threads on the metal shifter plate. No need for welding and looks much cleaner.

also with the longer Rod, shifting is way smoother and easier versus the short one.

 

Nice to see you have this completed.
Does anyone know what the 3rd sensor/switch on the TC is?

 

neutral.