Help with Savvy cable shifter

[jscheu]

Hello everyone,
I need some help. I've searched and can't find any mention of the problem I am having with my install. 2006 Wrangler LJ Rubicon. Everything is ok with the exception of the studs for the disconnects at the ends of the cable. On the shift lever end there is a bunch of slop between the stud and the lever with it tightened. It's like the stepped bushing is too small in diameter and also too tall. The transfer case end is similar but not nearly as bad. My wrangler only has 73k so I don't think that the holes in the levers are worn. The studs aren't long enough for a extra washer, which I'm not sure would help. Thoughts?
Thanks in advance, Scheu

 

[andy29847]

My Jeep is a Rubicon, and my shift kit was the 241 kit. The floor shift lever and the transfer case lever had plastic bushing that I had to remove. The the Savvy ends fit with the bushing first on the stud with the small side of the bushing fitting in the shift lever, the the washer on the other side of the shift lever followed by the nut. I used a 10mm wrench to hold the stud while I tightened the nut with a rachet and socket (13mm?).

 

[jscheu]

I did remove the factory plastic bushings. And I used the pictures in your thread to help get things routed correctly (big thanks!) It's like the new stepped aluminum bushings aren't the correct size.

 

[mrblaine]

Hello everyone,
I need some help. I've searched and can't find any mention of the problem I am having with my install. 2006 Wrangler LJ Rubicon. Everything is ok with the exception of the studs for the disconnects at the ends of the cable. On the shift lever end there is a bunch of slop between the stud and the lever with it tightened. It's like the stepped bushing is too small in diameter and also too tall. The transfer case end is similar but not nearly as bad. My wrangler only has 73k so I don't think that the holes in the levers are worn. The studs aren't long enough for a extra washer, which I'm not sure would help. Thoughts?
Thanks in advance, Scheu

Apparently the depth of the counterbore varies on the OEM linkage and levers. The pilot on the bushing winds up being slightly too tall. Remove it, sand, or file down the height of the pilot and that will let the ball studs tighten up. I have changed the height of the pilot several times making it shorter and shorter and we still find some OEM stuff that is thinner than the rest. Just bizarre.

 

[mrblaine]

I did remove the factory plastic bushings. And I used the pictures in your thread to help get things routed correctly (big thanks!) It's like the new stepped aluminum bushings aren't the correct size.

Correct enough to work in all but a few or you would see a lot more mention of the problem. It is also one of the issues that Novak had so I was very aware of it when I drew them up for Savvy. I have installed many of them and still find one every so often that the stamped hole in the levers are thinner.

 

[jscheu]

Ah. Ok. I was hoping Mr. Blaine would stop by and shed some light on the situation. I'll file them down tomorrow. Has anyone found the bushing to be a bit too small in diameter at the shift lever? Or once I get the height correct will that not be an issue?
BTW the Black Magic pads are VERY nice.

 

[mrblaine]

Ah. Ok. I was hoping Mr. Blaine would stop by and shed some light on the situation. I'll file them down tomorrow. Has anyone found the bushing to be a bit too small in diameter at the shift lever? Or once I get the height correct will that not be an issue?
BTW the Black Magic pads are VERY nice.

I've had the issue with both and the same on the 231 with the floor lever.

 

[jscheu]

Had some Jeep time this weekend. Carefully filed the bushing down till they were level and not protruding. Assembled everything, and the slop was gone.