A Different Kind of CDL Stuck Problem
 

Hey everyone! I've seen lots of thread where the lever was stuck, but this is not the case for me.

My lever moves freely between all positions, always engages hi/low readily, always engages CDL easily in low or high, and moves smoothly back to open....except that it doesn't actually disengage. The light stays on and it remains locked.

It takes a combination of rain dances, voodoo magic, and extensive sacrifices to the Land Rover gods (and a touch of luck) to finally get it disengaged.

What component would let the lever move freely while not actually disengaging lock? This is a 95 DI. Thanks!

I'd guess the little plunger switch inside the transfer case is 'sticky'. If the lever moves (and the linkage is not broken) the CDL is un-locking. The light in the dash is triggered by that plunger switch. Here is a picture of it courtesy of the AB website...

http://www.roverparts.com/product/img/Icn/PRC2911.jpg

Differential Lock Switch On Transfer Case (PRC2911 Same Fit As Part # PRC2911-LUCAS) - Land Rover switches/control unit/actuators from Atlantic British

That switch is just for the light, right? The light is fine, its on when engaged and immediately goes out when disengaged.

The problem is the lever moves to right place but the diff physically remains locked. I think there's a component along the linkage somewhere that has too much play and doesn't force it to disengage, was hoping someone knows what and where that might be.

If the lever is moving but the CDL actually remains locked (not simply a light on the dash), yes, your linkage is buggered. I misunderstood your explanation. I'm surprised it locks in the first place given this description. There are tons of CDL linkage threads on this forum and videos on Youtube that will be immeasurably more beneficial to you than anything I might be able to write.

Might want to check the connection at the CDL nipple and make sure it is adjusted and moving to both limits.

Check the plastic bushing on the actual shaft as well

you'll probably want to be in the garage when you check the nipples. don't want to get caught diddling your rover in public

Mine does the same thing sometimes but driving in reverse for a few feet always unlocks it.