Take this information for "face value" and use with your own discretion and wisdom.
First, let's see what we're starting with.This is the shifter, a Shimano 8 speed model that gives about 55 to 60 degrees of rotation. Along with it are the crimps for the cable sheath and the all important cable stop that we'll need at the other end of the cable.
The shifter boot up, I had the path for the cable figured out.
The index shifter is desgined to mount on a bicycle handlebar. I did not realize that the transfer case handle was a whole lot larger in diameter. So, I took a 1" piece of heater hose, split it, and then placed it around the handle. A bit of electrical tape held it in place. Then the index shifter was added to it and tightened down. This placed the index shifter in a very accessible place and also placed it at the correct orientation. The cable and housing were tie wrapped up underneath the body to the vent tube mounting bracket.
The cable came up into the engine compartment and was routed along the throttle cable. I tie wrapped it to the throttle cable to keep the profile low. It helped with running underneath the shroud that sits on top of the throttle linkage. I drilled the throttle cable mount with a drill bit bigger than the cable but smaller than the cable stop. This placed the cable stop to the outside of the throttle connector. Make sure before you crimp the cable stop on that the cable move freely through the sheath and that the index shifter moves freely as well.
The components for this project were bought at a local bicycle shop, the total cost was about $16.00.
Bob Kennedy - 1986 XLT Bronco
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