is it difficult to do?

 

E-Mail me your tele number and I will walk you thru it.
Mike

 

Hi all. 2004 D2 SE. I have a stuck diff lock. I have drilled out the rivets, put on blaster on the shifter and verified that my cable and tcase nipple both work. I’m now hoping to unseize the shifter. I’m not sure how to remove it from the truck. Do I remove both cables down at the transmission and tcase? Can I remove the cable hardware at the shifter? The cables look like the are not meant to be removed at the shifter. Please help if possible.

 

I’m not very good at describing it, but my 2004 had the same problem and it seems the 2004’s had an interlock mechanism that can fail and throw a locking pin in the way to prevent you from moving the shifter. I was able to gain access through the top as you have and then study the assembly and see how it should operate and you’ll likely see this pin. Rather than replacing the interlock, I just cut the pin. The result is I can operate the shifter at any speed/ any time which is not how it should be, but I’m ok with that. Wish I had taken pictures when I was in there, would have helped.

 

Hi Pete,

Thanks for your response. I'm wondering if you would not mind looking at this link www.discovery2.co.uk/Factory Diff Lock and looking at the diagram and picture in step 15. Is this the interlock you were talking about? If so, I might fix the same as you as I do not have $185 for a new solenoid.

Best,
Alex

 

Alex,
Yes that is the mechanism I'm referring to. You can almost see the 3/8" pin in both figure 15 and 16. It is meant to activate and lock against that lever. Mine failed in the lock position and I was unable to engage Low range.(out on the trail! )
I simply cut off the pin and am careful using the diff lever.
Pete

 

I had just swapped my 04 Tcase to my 03.
In my case, my linkage was getting very tight in the diff lock - I could shift - but I had to get out of the truck and heave over.
I had to pull the whole t case and linkage to swap - so when I had It on the bench I could see how the linkage worked in the case and the shifter - all my linkage in the case was 100%; I understand & have experienced these lt230 are pleasantly bullet proof - however my linkage pivots were seized.
I had to use heat and replace a few. But it was my linkage that was the culprit.