@mln01 I have an 04 and I find mine gets grumpy if I have not used for a while. 2 cables and 2 pivot points on the transfer case to get "gummed" up do not help. If I keep it well lubricated it does help a lot.

 

I'll throw this out there for internet posterity too... if you engage the CDL, drive for any length, and disengage the CDL, and the CDL light doesn't turn off, reverse the truck for a few feet and it should unwind the drivetrain and the CDL light will turn off.

 

Thanks guys. So there is no problem engaging low range on pavement as long as I go slow - correct? I was surprised not to see some sort of preventative maintenance procedure in the RAVE for the cables and linkage.

 

Yes slow in a straight line and don’t need to go far. I would suggest as others have to soak down the linkages with PB Blaster for a couple of days before you try. It will be stiff but don’t be afraid to force it a bit. It might take a few cycles to free up and be smooth.

 

Well, in a straight line doesn't matter with low range but it does with the CDL engaged.

 

Most of these trucks had owners that never used low range or the center lock so most of them are stiff or frozen. When I bought my disco, the hi-lo and center diff lock was super stiff and hard to engage/disengage. once or twice a day follow this procedure until it loosens up:

1. Remember to put the truck in neutral when going in and out of low range
2. It helps if the truck is rolling very slowly (1-2 mph) when shifting the t-case handle up into N, then into Low. (same when going back into High)
3. When moving in a straight line move the t-case shifter over to the left to engage the center lock. (taking turns are not recommended on pavement to protect your driveline)
4. A couple of seconds later disengage the center lock and wait for the indicator to disappear. (If it stays on, try driving in reverse for 100 feet or so)

It took me a couple of weeks until I could use my t-case easily.