I just raised my 98 Disco 4.0 from a very long slumber, and so far it's running very well, but the transfer case lever will not budge. Just FYI, my Disco was off the road since 2013, and has only had 10K Km put on it since 2007, so who knows when it was last shifted to low range or center diff lock. Do you need to remove the console to access the transfer case linkage? Right now the only things inside my Disco are the dash, console, and driver's seat, so now would be the time.

Cheers!

Phil

 

I think I recall adjusting mine from underneath, after having pulled the trans to replace the clutch.

 

need a good lubrication to free it up

 

Thanks, but lube where? I cannot see anything accessible from underneath, which is why I'm asking if I need to remove the center console.

Cheers!

Phil

 

Pull the rubber mat from around the diff lock shifter, twist the **** off the shifter (taking the gator with it). Now you should see a rubber 'plate' around the diff shifter. You will need to drill out the rivets which hold that in place.

Now you'll see the diff lock linkage, shafts, and splines. There is a splined shaft which should move right-left with the shifter. It is splined and passes through female splines. This is the area which becomes rusty.

 

Awesome! Thanks Walt. This was just what I was looking for.

Phil

 

I was able to get to mine from underneath, with a mirror, and a can of WD-40 with the long flexible spout (and skinny hands that don't mind getting greasy).

 

This is true but if it can’t be done, Walt’s option is the only other option.

 

Me too. Mine ('97) was also sitting for a long time (12 years) and probably wasn't used much if at all before that. It was pretty greasy and gunked up from a leaky engine on the surface and various joints but I was able to get up there with a medium-sized nylon brush and I think solvent first and then some sort of lube. Sorry don't remember the products I used but it was ultimately elbow grease to free it up. I used my phone I think to see around the edge but obviously a mirror would work as well. Now it's functioning perfectly and I try to run it through once a month.

Good luck!

 

My truck had also sat for a few years and according to the previous owner it was never used off road.

My transfer case selector was fine. My external linkage was fine. My issue was in the actual shifter mechanism. Heres a link to a little video I made once I got it working again.

https://photos.app.goo.gl/8v4Qxz1Yh72985nHA