Diesel Freak Twin Stick Installation

[USMC]

I finally installed the Diesel Freak Twin Stick setup in my Roxor.

It took me 30 minutes to remove the old stick and install the new sticks.

Removing the shift rod poppet spring and ball and then the front bearing cap was also about 30 minutes, just to take out the interlock pill. I had a 5/16 diameter magnet to remove these items.

I pulled my transfer case to do the work because I do not have a lift or a pit. If I had the 14mm crows foot I could have left the transfer case on the Roxor.

Takeaways:

1. Use a lift or pit with a transmission jack. I almost had a face full of transfer case.
2. Remove the transfer case skid plate. This and the jack will ensure that you do not mess up your Loctite sealant upon reinstallation.
3. Have steel poppet plugs available. I had to use a hammer and center punch to get the aluminum poppet plug out. After disassembly I found metal shavings in the threads from when the threads were cut. Torque King offers the Poppet Plugs in steel. Part # QU15525 they are also supplied in the Master Overhaul kit listed below.
4. Have a crows foot available in the metric size (14MM) for the front bearing cap bolts.
5. Have a 9/16 available for the rear driveshaft flange nuts. They are 14 mm but the 9/16 is much easier to use.
6. Make sure that you torque your twin stick bolts prior to installing the front driveshaft, it is just easier without the driveshaft in the way.

The twin sticks shift very hard because of the poppet spring. As Wade Lalone states, place a washer on the poppet plug for less spring pressure. I will be doing that today. Hopefully the mode stick poppet plug comes out easier than the Hi Lo poppet plug did.

Overall the set works fine and looks awesome. If you are a casual 4 wheeler this will work well for you. I think the KaiserWillys setup would be better for the hard core 4 wheelers. The Kaiser Willys sticks are back by the seats.

But, I will be putting the KaiserWillys Twin Stick system in in the near future (I purchased this kit before Diesel Freak came out with theirs). Since Diesel Freak came out with this quick setup I thought I would try it out. I will also be rebuilding my transfer case with the Torque King Kit. TK2034 Mahindra Roxor Transfer Case Master Overhaul Kit

March 27, 2026

I went to Ace hardware and picked up two 3/16 thick washers and two 3/32 thick washers. I used one 3/16 inch washer on the HiLo shifter poppet plug and it did wonders for being able to shift from Hi to Lo and back.

Tomorrow I will install the same thickness washer on the mode stick poppet plug.