Hi all,

I've got a 2003 td5 d2a and sometimes I find it hard to move the transfer lever into low or high range. Sometimes I can shift straight from H to L, but sometimes I can only do it by double clutching (clutch in, shift from H to N, clutch out, clutch in again and then shift to L). It also shifts fine if I slowly roll, less than 5km/h, which I read on the internet is what many other people do.
Transfer case never drops out of high or low range and once it's in it works perfectly fine, no whining noises etc.
Is that a normal or common? Previous owner said he had never used the transfer lever so the linkage could be a bit seized from not enough use but I've tried greasing the linkage.

 

First off, I'm uber jealous of your td5 mated to a manual trans.

My '01 auto trans gives me a fight sometimes. Just rock the truck a little and she slips eight in. Food for thought, I have a 170k miles on my rig.

 

Best you can do is keep working it to see if you can free it up any.

 

Feel bad for you Americans driving petrol guzzlers

It seems to shift easier on really hot days. I'll try changing the gear oil and keep greasing up the linkages to see if that helps. I'd like to hear how other people fixed it.

 

How much does a td5 cost over there?

 

from about $10,000 for early ones up to $20,000 for facelifted models... yeah, cars and everything is much more expensive here
us$ and au$ are pretty much same these days

 

Could it be the solenoid preventing it from shifting? I've found out some people removed theirs

EDIT: nevermind, only north american and jap discos have interlock solenoids

 

We hot another spammer!!!
WTF?

 

Changed transfer box oil today and wd40'd the hell out of linkages. It made a bit of an improvement but it still doesn't go sometimes.
I did find out though that it shifts from high to low fine if I don't use the clutch which is strange

I know many people have similar issues and noone seems to be able to figure out what's causing it. Most people just live with it and either shift when the car is slowly rolling or double clutch it or with autos put it in drive and shift. I know it's a bit of a first world problem but it's giving me the ****s lol.

 

Are you shifting when the truck is in neutral/clutch depressed?