Thanks so much for the info and pics. I was not able to get to the truck today. I will try it tomorrow morning. THANKS AGAIN!!!

 

I will be monitoring this thread from about 8:15am on Andrew, if you need me to look at something or try something on mine let me know

 

So others are aware the problem is the plate has gone past the nipple see image below sent by Andrew to via text msg :

 

So it’s the locking diff that’s the issue. I thought it was the hi low

 

@redwhitekat on 03/04 that is the hi low part - the problem is he can get under the upper arm then it will not move

 

Ok I see. I just had the experience of putting all these linkages together on my 03. But I took that solenoid out of the system and kept the one at shifter.
I’m sure there is a way reaching pushing that solenoid pin in and pull that cable.
Looks like a real pain

 

@redwhitekat he can get the pin in but the linkage will not move beyond the low position something else is up

 

Well here is where he is at -

1. He can get the Hi-lo to sit on top of the interlock Plunger - low gear position
2. It will not move beyond that

What are we missing here - does the plunger need to go in further ?

 

i would somehow get the wheels of the ground and or try and pull that lever back with the truck rolling slowly
sometimes or your not really suppose to move the high low with the vehicle in a stopppec position.

Just out of curiosity did all this happen due to solenoid failure ?

Anyway it should move with truck rolling

 

@redwhitekat I had him try that no luck, it is a new transfer case so I am thinking that the interlock is not releasing Which may be that little pin not being far enough in to release. I wish there was a clear description on how that thing works.