Hi guys, I wrote up a post and submitted it with attached photos which apparently get filtered out and don't actually post. so trying this again...

I recently bought a 96 v8 auto disco1 from someone who let it sit for years in his yard.

unsurprisingly the center diff lock is stuck. I disassembled and rebuilt the shifter box/linkage but the arm on the t-case is still fully stuck.

i removed the CDL switch plunger thing, and it was very bent.

Even with the plunger removed completely the arm will not move, so i took the 3 bolts out to remove that.

Nothing is visibly broken peeking down that hole, but I'm also not familiar with this t-case.

Anything more i can do without dropping the whole t-case out of the truck?


I'm still sorting some engine issues so i haven't really driven it, but the quick test drive prior to taking anything apart, the t-case does get into low range and back into high, just had no CDL.

Any experiences with this? it's too bad it wasn't just a seized shifter box because that was fairly easy.

 

i guess i can pull out the detent ball/spring next, and if that doesn't allow movement of the shifter fork, time to pull the side cover?
Can i pull the side cover without dropping the case?

 

Soak it in ATF or penetrating oil etc.

 

I am having a little trouble understanding so I want to clarify a couple of things...
1- you pulled out the shift linkage through the center console of the truck, cleaned it all up, greased, and re-fit. This makes it certain that the impediment is not in the mechanical levers. The splined shaft moves freely right/left when removed from the truck.

2- You CAN shift the xfer case from Hi to Lo and back (moving the stick inside the truck forward and backward

3- You CANNOT move the stick inside the truck right/left (which locks the center diff) once it has been re-installed in the truck

Is all that correct?

 

I'm assuming I wrote in a manner that was confusing. Let me try to clarify below.

1. yes, shift linkage is fully cleaned and regreased and moves freely in both directions outside of the truck

2. yes, high-low function works.

3. correct, so currently the entire linkage has been removed from the truck again. I have attempted to move the arm coming out of the t-case, and that will not rotate in either direction.

 

So this means the CDL function is stuck/broken internal to the t-case.

The first thing i did after removing the linkages was to remove the CDL switch (plunger sensor thing) which was obviously bent (cannot add a photo to this post because i don't have enough posts yet)
even with the switch removed, the arm will still not rotate.

so I pulled the 3 bolt flange containing the arm and shaft, and tried to move the shift fork bar thing inside the t-case with my fingers.... which also does not move.

 

Pull the side cover that's right next to the diff lock selector you removed. There is a shaft that the finger fits in and it's bushed and seized, hit it with PB or WD40 and let it soak awhile. Give it a couple of shots over a day or two and then see if it'll move. The switch you removed probably wouldn't retract which is why it's bent. Paul Grant is in my signature, contact him if you need parts.

 

these may help

 

finally got a chance to poke around again, but unfortunately doesn't look like it's possible to pull off that side cover without splitting the t-case from the trans.
...which for right now puts it lower on the list of things to do.

I wasn't able to take a photo that shows it but the shift rail appeared to be cockeyed viewing from above... which would explain why it is seized.
But I'm not sure how it could have gotten bent.

Either way it seems like it has to wait until I fix up all the other issues on the truck first.

Thanks for the input and video links

 

take a flashlight and look between the t=case and the brake drum.See if the nut and keeper are still there and not broken at the main t-case shaft.I have seen the nut gone and housing chewed up because bearing went bad.This will make shifting lock up and no fix only replace.also look in same spot on front side of t-case and see if any obvious damage to case at main shaft site.The t-case i just pulled had all the same scenarios as you are describing finally i pulled it found bulged top of transfer case broke through and both ends of main shaft chewed through the t-case housing.