04 D2 Diff Lock Issue

[Batrover]

...was troubleshooting the lack of illumination of my diff lock light on dash when locking diff. Pulled switch and found that through the hole I CANNOT SEE THE
SPRING on the shaft— when locking, I can see movement, but without the spring, the fork doesn’t engage the lock. I have engaged the lock while driving to listen for the fork engagement, but I don’t hear it engage when the front wheels move. My question: is it possible to remove the front output housing while it’s in the truck? And secondly: how does the spring completely disappear... thanks for you wisdom in advance.

 

[Batrover]

...anyone...?

 

[squirt]

Yes, it's completely possible to remove the output housing without removing the T-case.

Which spring are you talking about? #18 below? #13?

 

[JUKE179r]

I never opened up the t-case but when I engage CDL with a 10mm wrench at the nipple (I have a 2001 without the linkages), I let my Disco roll a bit. This allows the CDL to fully engage and then the light illuminates to indicate it is engaged..