Transfer Case Gear Lever - pin

OGrid · Jan 18, 2024

Wondering if anyone else has/is encountering an issue where a very small metal pin (I’ll call it a pin), is sticking out of their transfer case lever near the top around the ball?

The pin appears to not only hold the gear boot up the top of the lever but also plays a significant part in the functioning of the gear lever and its ability to select low range etc. How do I know this? I found it striking out and had a look at it, it then promptly fell out onto the floor and I could no longer use the transfer lever and it was stuck in place.

I was able to locate the pin and once inserted I was able to move the lever again (though it still sticks out). I’d take a photo of it sticking out but it was at night and the next morning dropped it off to the dealer for a few other issues to be rectified.

bakepl · Jan 18, 2024

Yes well reported. Some are placing a zip tie around the lever so it doesn't come out. Not ideal but....

OGrid · Jan 18, 2024

bakepl said:
Yes well reported. Some are placing a zip tie around the lever so it doesn't come out. Not ideal but....

Ok, thanks. I’ve obviously missed that.

Max · Jan 18, 2024

OGrid said:
Wondering if anyone else has/is encountering an issue where a very small metal pin (I’ll call it a pin), is sticking out of their transfer case lever near the top around the ball?

The pin appears to not only hold the gear boot up the top of the lever but also plays a significant part in the functioning of the gear lever and its ability to select low range etc. How do I know this? I found it striking out and had a look at it, it then promptly fell out onto the floor and I could no longer use the transfer lever and it was stuck in place.

I was able to locate the pin and once inserted I was able to move the lever again (though it still sticks out). I’d take a photo of it sticking out but it was at night and the next morning dropped it off to the dealer for a few other issues to be rectified.

View attachment 7840288

I can't see on my Shifter where that is...would you take a pic please?

Edit: I just felt a hole on the backside of the shifter...thank you I am with it..maybe a dob of Sikaflex

[ Adam ] · Jan 21, 2024

Yes, mine started to come out so I zip tied it. This has had the unfortunate result of the classic dealership response of "we can't get it to fail..."

I guess I'll need to just let it fall out and let them pay the tow bill to move my vehicle from NoVA to Philly since it'll be bound to happen in low. /Sarcasm

lagartoboy · Jan 21, 2024

OGrid said:
Ok, thanks. I’ve obviously missed that.

OGrid, can you report back with how the dealer fixes it? Thanks.

Andiamo · Jan 21, 2024

What about putting a small piece of black electrical tape over the pin site? Could just be a small square, no one would see it and seems like cheap insurance (yes it shouldn’t happen at all). Or would the pin simply push through the tape?

[ Adam ] · Jan 21, 2024

Unknown - I prefer the zip tie as it won't fall off. The last tech to inspect it used a quality black Nissan reusable zip tie.

They tried to pull the pin out with a magnet and it would not come out. I'm honestly unwilling to allow it to fall out again, as it may significantly disable the vehicle if lost.

Andiamo · Jan 21, 2024

I may just put a square of black electrical tape there just as a belt-and-suspenders approach. Mine doesn’t seem to have moved but wouldn’t want it falling out at the wrong time, or anytime.

Krabby · Jan 21, 2024

Has anyone removed the pin and found a better fitting alternative?

Asnes · Jan 21, 2024

If it falls out maybe re-insert with a light coating of clear silicon to keep it stuck in place? I don’t have my truck yet so just a hypothesis…

lagartoboy · Jan 21, 2024

Andiamo said:
I may just put a square of black electrical tape there just as a belt-and-suspenders approach. Mine doesn’t seem to have moved but wouldn’t want it falling out at the wrong time, or anytime.

And while you have the black electrical tape put a strip over the annoying passenger airbag light as another member suggested

.

Mountain4x4 · Jan 22, 2024

lagartoboy said:
And while you have the black electrical tape put a strip over the annoying passenger airbag light as another member suggested.

Also good for covering nagging check engine lights!

OGrid · Jan 22, 2024

lagartoboy said:
OGrid, can you report back with how the dealer fixes it? Thanks.

The dealer placed the pin back inside the shifter. The dealer’s comment was that Ineos had not, at that time, identified a solution to stop it reoccurring.

They said they’d not seen an issue until approx 2 weeks ago - I was their 4th issue encountered. I’ve done 5200 kms.

Mountain4x4 · Jan 24, 2024

I really hope Ineos is on here. Something even simple like this, could be discovered and fixed before it becomes a big issue. I think dealers are slow to communicate problems they do not see as a major safety issue. This forum can replace millions of dollars in losses down the road, improve customer service, understand customers further and replace millions of dollars in useless focus groups. The cost? A couple of hours of labor a day!

Hannes01 · Jan 24, 2024

I had the same problem.
As the pin was not available separately, the whole gearshift was replaced.
If I remember correctly, the pin is 24x3 mm.
I'm going to get 3.1 mm dowel pins as a replacement!

Tazzieman · Jan 24, 2024

Mine's ziptied and thus fixed

ORSO · Jan 24, 2024

This is my temporary fix

DaBull · Jan 25, 2024

Hannes01 said:
I had the same problem.
As the pin was not available separately, the whole gearshift was replaced.
If I remember correctly, the pin is 24x3 mm.
I'm going to get 3.1 mm dowel pins as a replacement!

Let us know how easy the new pin install goes and where you purchased one.
DaBull

TCMColorado · Jan 25, 2024

Hannes01 said:
I had the same problem.
As the pin was not available separately, the whole gearshift was replaced.
If I remember correctly, the pin is 24x3 mm.
I'm going to get 3.1 mm dowel pins as a replacement!

A spring pin is definitely the best solution. Easily sourced in the US from McMaster Carr. The linked pin has an actual diameter of 3.3mm and will compress for use in holes from 3mm to 3.1mm. The issue might actually be removing it if the need arises.

https://www.mcmaster.com/91610A411/

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