1998 Disco Reclamation project

Found this link on the forum that was very helpful: http://home.twcny.rr.com/eeibooks/ro...codifflock.htm

Transfer case selector was completely seized. I yanked out the console etc and found a small amount of rust/corrosion (see picture)....ouch!
I think the previous owner parked the truck in the ocean for a few weeks!
Sprayed PB, waited, sprayed waited, etc. Got impatient and yanked out the shifter mechanism for further soaking. (needed to drill out the pin between the shifter and linkage)
Now that the shifter is out of the way the diff lock engages easily with a 13mm socket (light comes on anyway)
Now in regards to the high/low range engagement, with the truck in neutral with the key turned on the linkage seems mighty frozen.
I have attached a picture showing the bottom of the linkage where it goes into the transfer case (that should rotate easily right?)
It is very corroded so I am soaking that with PB and hopeful there is not a problem with the solenoid.
Any tips how I can test the solenoid to know whether I am fighting corrosion, solenoid or both?




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Open up and clean out the knuckle box the the shift hooks into on your first pictuer. That is usually where you will find the problem.

 

my truck can only engage low range with the truck rolling in neutral at 1-2 mph... its not like the center diff, i can lock and unlock that stationary with the engine off... but the high low selector i am pretty sure is not gonna engage unless you are running and rolling... i could be wrong but that is my personal experience...
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ASIANONSTOPCUM

 

Mike when you refer to the "knuckle box" I assume you mean down on the transfer case where the linkage engages
There are four bolts holding it down and a cable of some kind.
I was curious if that could be easily removed and freed up.

 

In fact there are 6 bolts. I had to take it out to free my linkage. When the bolts are out it is supposed to be easy to remove. And it is not a cable... my guess goes for a vacum hose of some sort.

 

Thanks Jull.
I have been spraying the area where the lingage goes into the "knuckle box" (Rave calls it the high/low ratio cross selector) a few times a day. (It is extremely corroded)
Once the main shifter mechanism (transfer gear selector) is completely happy in the up and down as well as side to side I will pop it back in and try the high/low again.
Using that gets the force on the linkage in the right direction.
If that doesn't work I'll yank the Knuckle box and if that doesn't work I'll sort out the solenoid.