After a day of fiddling with the stupid t-case and cdl...

[RoverbyProxy]

Ok, spent the day trying to get the t-case low range freed up and fixing the cdl on our 95 D1.

One question, the shaft that connects with the handle then connects to the splined range select lever and the cdl select vertical lever, is that supposed to slide horizontally?

Because mine doesn't and I cant figure any other way to engage the cdl.

 

[crown14]

They seize up in the endplate with the two big screws. Remove the shifter assembly and then you can loosen that part and lubricate it properly.

 

[RoverbyProxy]

Yeah, I did that earlier, as far as removed the screws. It is in there so tight that it seemed like a pressed fit so I went back out there to see if I was missing something. Only thing that's missing is my ability to not over think the simple.

Anyway, I have it soaking in some penetrating oil to hopefully loosen up.

Does the cover over the hi/low selector come off the transfer to reveal anything the might be stuck, ie; shift collar?

 

[DarylJ]

Does the cover over the hi/low selector come off the transfer to reveal anything the might be stuck, ie; shift collar?

You can see the shaft that moves left/right as well as the high low linkage when you take it off. I've found that taking it off and cleaning the nastiness out then soaking in penetrating lube (or just filling it up with acetone and ATF) overnight helps a LOT. Once it's freed up I load it up with grease so everything stays protected from the elements and slap the cover back on. On the half dozen I've got working again this way, all of them have been like butter afterwards (of course only after freeing and lubing the rest of the CDL linkage down to the t-case).

I will admit to taking a soft mallet to at least a couple to beat into lock, and then back out again (with the linkage disconnected) several times before they loosened up. If you go this route, keep your blows as low as possible to avoid bending the shaft and don't go totally medieval on it. If it won't at least start to move with a few stout blows you probably need more soaking.

 

[crown14]

It is in there so tight that it seemed like a pressed fit

When it sits in a certian position it binds up so yeah it will be tight. It will feel completely solid, and penetrating lube will only help get it loose with the correct technique. That's why you need to loosen the part at the end of the shaft. Really you need to pull it all apart and clean it up, make sure there is no excess wear on anything that would cause it to hang, and lube the shit out of it with fresh grease.

Cover off the high low selector?

Once the assembly is out of the vehicle and securely in a vise it gets much easier. You can see how it all works and its obvious what you will need to do.