Hi,
Looking for some help on my 2004 D2. The cdl lever gets stiff now and again so I spray the linkage underneath and work it to free it up.
The last time I did this the lever would not free up and broke off a piece of its detent. I have the truck up on my lift and have removed the lever assembly out the bottom. I have disconnected the cables and have try to move them by hand but no luck. My question is could the cables be that bad? and I have not found any one that sells the cable or a original lever. Also I can not get to the Hi/Lo cable where it attaches to the transfer case. Do I need to drop the transfer case to get to it. Thanks, any insight would be helpful

 

Cable is absurdly expensive and can get corroded, yes. If you have to replace the whole assembly the Ashcroft unit is the cheapest for OE look/use, you can also use a D1 version.

 

It can be accessed from the top. Remove the center console (Lucky8 CDL install vid on youtube shows how) and drill out the rivets that hold the cover to the transmission tunnel. I had to free up my cable with PB blaster and also used a craftsmen auto hammer to lightly impact the outer steel housing that the cable resides in. Selector on T-case will be accessible from the top too if it needs to be lubed.

Have you tried shifting while slowly rolling, under 5MPH?

 

Thanks for the input so far.
I did see that plate floundering. That will be my next step. It looks like I will get the Ashcroft shifter that ZGPhoto mentioned. I did try shifting at the low speed. The shifter was just froze up. Thanks again.
I've had this thing for 5 years and like the truck, It just likes to have a fit now and then.

 

The less you use the cdl shifter, the more likely it is to freeze up.

See if you can service the cable before spending the $500 for the new ashcroft setup.

Lucky8 has the best price on it at Lucky8 Llc. - Take the road less traveled...

 

If it's hi-lo that doesn't work, I'm guessing solenoid.

 

Isn't that the truth! I got me a D1 linkage off of Ebay and the thing wouldn't move AT all. Froze to the point I thought it would snap, and probably would. PB-Blaster bath overnight for a couple of nights and finally I could get it to wiggle. Wiggled it millimeters at a time for well over and hour and finally she broke free. Cleared out all the old lubricant and substituted it with hi-temp lithium grease purchased for the front drive-shaft.

I'm wondering if part of the freezing is temp-related like the front-drive shaft failures. The linkage seems to be in a fairly high-temp area, if Solihull stuffed in a typical room-temp style lubricant coupled with general lack of use, I could easily see this thing binding up over time. I'll report how the hi-temp grease holds up, but once installed I plan on using it, so hopefully it won't freeze on me again.

It's a solid design, but like I'm learning very quickly with the disco, one stupid design mistake (generally chosen for economic reasons) transforms something that should be trivial and robust to a massive headache....

 

after you get the cables freed go to a bike shop and buy the lubricating kit that is made for motorcycle cables.

 

If you are talking about one of these http://www.powersportsuperstore.com/...tm?Click=35177

The disco cable is too large in diameter to fit into the tool.

 

Oh man.
I have used mine about 5 times just to show prospective buyers how it works.
Everyone wants to be "the man" and shift that lever.
Glad I have used it.