Tools and miscellaneous supplies that you will need before getting started;

1). A ¼” or 3/8” drive ratchet, a ¼” or 3/8” X 3” extension and a 10 mm socket, to remove the 6 motor and bracket mounting bolts. A 10mm nut driver will also work, assuming that the shift motor bolts are not torqued too tight.

2). A small, thin blade flat tipped screw driver. This is for lifting up the tabs on the multi wire connector that goes to the electric motor so that the coupler can be separated.

3). Wire cutters, to cut the three other non-coupled wires at the speed sensor.

4). Some electrical tape.

5). Some thread lock (Loc-Tite or CRC brand) or some Never Seize for the three new bolts for The Shiftster. The choice of which product to use is entirely up to you. Personally I like the Never Seize even though it means I need to check for loosening bolts more often. But a drop or two of thread lock will help retain the bolts longer. Again, it’s your choice.

6). And finally some grease to lightly lube the triangular transfer case shaft and the end of the locking pin (socket head cap screw). This would also be a good time to try some synthetic grease if you’ve been looking for an excuse to buy some. Mobil 1 works very well.

Ok then, once you have your tools and supplies ready, it’s time to install the Shiftster-1.

A). Start by finding a nice clean, flat spot to park your truck so you can work comfortably (unless of course you are already out on the trails and are installing the S-1 as an emergency repair). First, make sure that your vehicle is in 2-High. Now put your transmission in park and set the emergency brake. Or if you have a manual transmission put it in 1st or reverse and set the emergency brake. .

B). Next make sure your ignition key is turned off. Even better, remove it completely until you’re finished. Now go under your truck with your tools. First thing to do is to cut the 3 wires at the speed sensor, preferably in the middle so there’s enough wire on both the truck and the electric motor in case the next owner wants to splice them back together some day. Now grab your thin screw driver, gently pry up the tab on the multi-wire coupler and pull them apart. The remaining wire harness on the truck can be zip tied up and out of the way on the driver‘s side of the rail very easily. If you’re worried about corrosion of the terminals, it may be a good idea to pack the terminal with a bit of grease to keep moisture out. Also you can always use a very small Ziploc baggie to cover the wire coupler with a second zip tie to really seal it from the elements.

C). Now you can take your ratchet and socket and remove the one hex bolt at the lower end of the motor housing and the two bolts that hold the wiring harness bracket. Again, these should require a 10 mm socket, but sometimes you just never know what a previous owner has done. Now remove the three longer bolts that hold the motor onto the transfer case. Make sure you support the motor with your other hand so it doesn’t fall down on your face. Or worse. Now remove the motor, toss it in a box with the other bolts and screws and put it away somewhere. Because hopefully you will never see it again. Congratulations, you have just put a whole bunch of electrical components and their associated nastiness out of their misery. And yours.

D). Ok, here’s the fun and easy part. First verify that the triangular shift shaft on the transfer case is pointing to the ‘2 HIGH’ mark. If it is not, you can use the Shiftster in lieu of a pair of pliers to help turn the shaft. If the shaft will not rotate back to the ’2 HIGH’ position, then try and turn it to the ’4 HIGH’ or even the ’4 LOW’ spot. If you do this though, just remember to rotate the Shiftster to the corresponding position as well before you attempt to mount it (the Shiftster’s are pre-set at the factory and shipped so that they are in the ‘2 HIGH’ position). Now dab a little bit of grease onto the triangular shift shaft sticking out of the transfer case. Next put the three 6 mm x 16 mm hex machine bolts through the three holes in the mounting plate and then place a drop or two of thread locker onto the ends of the bolts. Now place the Shiftster over the shaft and flush to the transfer case housing. Turn the mounting plate a bit if necessary and make sure that the three holes in it match up to the holes in the transfer case. When they do, you can now install the three mounting screws and gently screw them in finger tight, alternating from one to another so that the pressure is even. Now snug them up with either your ratchet wrench or nut driver. Caution, you won’t need to torque them down too much, maybe 6-8 ft lbs at the most. Remember, slightly loose is always more preferable than breaking a bolt or screw off. Trust us on this one.

5). Step Five. Well there really isn’t a Step Five because…….congratulations, you’re already done. Except for maybe cleaning up and then going for a drive out on the trails. Which is why you did this in the first place, yes?

We hope you enjoy your off road adventures and our product.

Sincerely,

The staff at The Shiftster.
Click Here to contact us if you have any more questions or comments.
Call us at (310) 4000-4X4