Hey everybody. I recently finished my ACE LS swap (had the kit for over a year but only recently had the time). Went to go out and tune the engine but lo and behold the transfer case detonated on me. When replacing, I found that the transfer case shifter assembly was rusted COMPLETELY for the CDL portion of the shifter. I can go from high to low but not from CDL to unlocked. I’ve been soaking it in PB blaster and using heat where I can but it is rusted BAD. Unfortunately I need a unit out of an 04 because the 99-03 don’t have the CDL control option.

If anybody happens to have one or a parts truck, I would love to buy a replacement. I’ve checked all the junkyards around here and their 2004’s have been picked through pretty badly and the next closest junkyard with a 2004 is over 150 miles away. I would even be willing to pay somebody to get the part from your local salvage yard and ship to me. Any leads would be appreciated.

 

I have one. I will PM in the morning.

 

Wow really? That’s fantastic! Look forward to chatting.

 

PM sent

 

I have been able to save rusted 04 CDL assemblies. You gotta soak em and tear them down as far as possible, then put it in a vise and work it with heat. It will eventually break free and you can get it working. I've saved probably 3-4 that looked way worse.

 

Hey Best4x4, I’d love to give it a shot and save another one. I’ve tore it down as far as I can figure. I knocked out the 2 roll pins in the lever but can’t seem to get the shaft out of the housing. The plastic bushings on the ends of the shaft don’t seem to want to budge