Engine/Transmission (1998.5 - 2002) BD Short Shifter Broke

[jdross440]

Got in my truck this morning, started it and shifted to 2nd (I leave it in 1st when parked) and the shifter broke off at the base of the thread. See picture. Luckily I still have my original parts. This has been in the truck since 2002 and has about 240K miles and one transmission rebuilt. I need to find out if a replacement stub is available for the BD kit.

 

[RBeard]

That happened to the original shifter in my 01' after about 200k. Mine had rusty areas around the break, like it had been cracked for a while before it broke. The threaded area is the weakest point after it is machined and threaded. I replaced mine and used blue Loctite and didn't overtighten it

 

[jdross440]

It broke where the threads end. There is a design flaw at that point. They should have machined a radius there (like original has). By threading all the way, when the die hits the ring it puts a stress riser at that point allowing for fatigue and vibration cracking to occur.I am surprised it lasted as long as it did. Being a retired Aerospace Engineer we would never design a thread to end like this one does.