Stuck Diff Lock and High-Low - Pics and Tips
 

Hi,
Yesterday I tried to post an extensive post on my diff lock and high-low repair adventure, but I think it was too big and did not seem to go through. I read most posts and articles on fixing this, but could not find certain key pics, so I am offering mine up for anyone who finds them useful.
I also had to do some rework, because after fixing my diff lock my high-low still wouldn't work. I removed the solenoid as most people find it is the problem. Long story but it wasn't the solenoid but the actual linkage arm, so I followed Paul Grant's advice and removed the high-low cover as well, and cleaned and lubed everything. Now everything works perfect, it seems even better than when I got the Disco in 98. Please let me know of any questions. I have many details and tips but don't want to overwhelm one post.

Phase 1: Removed linkage and fixed shifter, cleaned and greased nicely; seemed to work well and re-assembled.

[IMG]http://i1370.photobucket.com/albums/...psff52a5e2.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...psdf7a0275.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...psb5fb7753.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps38f2f678.jpg[/IMG]

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[IMG]http://i1370.photobucket.com/albums/...ps629d8045.jpg[/IMG]

Phase 2: After fixing the diff lock the high-low still didn"t work so I tried the solenoid and eventually removed everything again and fixed the high-low arm that comes out of the cover. For phase 2 I had to dig deeper into the tunnel by removing the autoshifter and plate.

[IMG]http://i1370.photobucket.com/albums/...ps2c255325.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps0026d52c.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps13c17c21.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps9df6c308.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps1fd06896.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps00a73e68.jpg[/IMG]

[IMG]http://i1370.photobucket.com/albums/...ps9e5e66ef.jpg[/IMG]

Thank you for posting the pictures!
John

if the diff lock light switch on the t case is screwed in too far it will also jamb it , just fyi

Thanks. I didn't know about the light switch but everything seems to work fine now.