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Okay you have an 03 you DO NOT have to gut the interior to push the interlock solenoid back on an 03-04 assembly. With two people (one inside the D2 & one under it) you can manually push the interlock solenoid back with a long long bladed flat blade screwdriver, or some other stiff long device of your choice. Removing the front drive shaft would certainly make the view easier, but it can be done without removing it (your choice). If you look up from below you will the 4Hi/N/4Lo shifter assembly. You will see the round area with a wire lead coming from it. Now on the other side is the linkage that goes forward & back. Between that linkage and the interlock you will see the tip of the interlock solenoid blocking the linkage from going forward & back. Simply reach up with something long & stiff (will probably regret saying that later lol....) and manually push it back while the person inside has the D2 in N with the parking brake applied they should be able to go from 4Lo past N and into the 4Hi position. Now you are out of 4Lo and can drive at regular highway speeds.
Or if it's freezing I guess you could gut the interior console, drill out 13 rivets, and manually manipulate the interlock solenoid from above.
**** I feel like I should print this out and put it in our gloves boxes for that "just in case" day. Good info sir!
@Best4x4 He is heading back home to Vancouver, once he is back I believe it will going to the shop that put new transfer case in last fall. Thanks for the offer he may take you up on it or if does not I might.
Just an Update ACG is back on the road in hi, it appears the cable is compromised. The mechanic was able to get at the lever from underneath on the hoist, remove the cable and put the disco into hi.
Thanks everyone for your suggestions and help
I believe l mention removing the cable and moving it manually in post #10. Removing the driveshaft makes it very easy to reach.
Do you guys replace the rivets upon reinstall or replace with bolts?
i used sheetmetal screws. since it was a retrofit and that might mean that i would need to get in there again, i figured that screws would be easier to deal with than having to drill out another set of rivets.
@The Deputy They had to go in from the back and disconnect the cable at that end and then manually move the actual selector level. He got the cable off the front but it would not budge. You can reach it from the ground going past the resonator but there is no easy to see what you are doing.
Red circled arm is what actually moves the "Gear Fork"
We decided against heading further north to the Arctic Ocean and will head south. We are leaving the Yukon today. The truck is back in non-CDL high. There appears something screwy with either the linkage assembly or the cable. But I am not chancing another issue with the transfer case shift mechanism. My son also has to be back in school on Sept 3. We are going to take a lesiurely route via Jasper National Park (which is new to us) to make it home to Vancouver.
Thanks again for your help!
P/S. Best4x4, I will take your offer of your shift cable linkage. I believe I will need it once I am able to tear into the center console when I get home. Time to also replace the rivet nuts with screws for easier access as some have suggested.
