Cant shift into low?

[vaden87]

I am working on my girlfriends 96 DI that has never been off road - I am getting it ready for the trails this weekend. The truck shifts into Hi/locked fine (light even comes on) but the truck will not go into Low or Low/locked. I can not get the CDL into Neutral either. I have searched for a few hours and have not really found anything useful about hi/low. Everything is about Hi/locked. I did read about the solenoid going bad and the linkage siezing. But I didn't know if this was a possiblity. Do I need to remove the center console in order to remove the solenoid?

Thanks

 

[vaden87]

If I can lock the diff then can the solenoid be stuck?

 

[vabiro]

Ryan,

It sounds like the CDL lever is siezed. This is really common on D1s that have not had regular use of the CDL. You may be able to free it up by getting under the vehicle and spraying some WD40 or other penetrating oil, but do not force it. You can break the lever if you force it.

Unfortunately, to fix them properly you have to take off the centre console, and drill out the rivets holding the surround plate for the CDL lever. Then remove the CDL lever and add some lubrication to loosen it up. If it is relly bad, it may need replacement. I think someone on the Dweb For Sale forum had one for sale.

Hope this helps.

Victor

 

[blkbear]

Victor from Toronto is right on the money. Had the same problem with my 95 D1. Once the centre console is removed you can take the shifter apart, clean it up and regrease it. Took a couple of hours to do mine. Saw the same thing six months later at the OVLR birthday party. A fellow from Tennesse (SP?? - sorry!) He thought he was going to have to drive from Ottawa to tennessee in CDL low. He was a bit worried as he did not have the 3 weeks it would take to cover the distance in low.
The shifter was stripped down, cleaned and regreased in a couple of hours. He was easily able to shift ut of CDL low and into high for the ride home. He was much relieved.
The long and the short of it is that it can be loosened up in a couple of hours.

Brian

 

[vaden87]

Thanks guys!

I thought it couldn't be the solenoid since i was able to lock it in high.

Since she has had it, she has never been able to put it in low and I am pretty sure the previous owners didn't use the low gear at the mall.

We are going up to tennessee tomorrow in her rover for a little trail riding. I guess Ill fix it when we get back. I took my rover last time and it wasn't anything bad. Hopefully we wont need low gear tomorrow...

You may be able to free it up by getting under the vehicle and spraying some WD40 or other penetrating oil

What part am I looking for when I spray under the truck or is it obvious once I get under there?

 

[maxyedor]

When I bought my 98 it was a soccermom-mobile and the diff did the same thing, I just sprayed WD-40 on it from underneeth and worked it in by moving the lever around a bunch, it has worked great ever since.

 

[vaden87]

hopefully I will have the same results - thanks again

 

[k12]

why not spend a few hours getting it fully operational now in the comfort of your garage? To do it on the trail, or to be pulled out all day will suck!!!

 

[vaden87]

why not spend a few hours getting it fully operational now in the comfort of your garage? To do it on the trail, or to be pulled out all day will suck!!!

I am going to spray under the truck before we go and if that doesn't get it, i will tear into it when we get back

 

[k12]

By the way, that is hot that your G-friend has a D1! My wife loves our '98 D1 so much that I only get to drive it on the weekends when she doesnt have it. ha ha. Chicks in Discos are the Best (especially if wheeling them).

I remember the first time she forded across a fast little moutain stream. I was so proud. She is always amazed, as am I, at the capability of a stock D1.

Have a blast this weekend!

 

[LiveAtTheEdge]

just a heads up, this problem happened on my XD, and i was told by the dealer that lack of use was the reason, however, someone had had the transmission out and when putting it back in hadn't lined up the transfer case correctly so it wouldn't go in for that reason. Hope u get it all working smoothly.

-Jack

 

[96DiscoSE7]

go here..... all the info you will need -Andy
http://home.twcny.rr.com/eeibooks/rover/discodifflock.htm

 

[vabiro]

go here..... all the info you will need -Andy
http://home.twcny.rr.com/eeibooks/rover/discodifflock.htm

I'm not crazy about his order of operations.

I think beginning with crawling under, checking that the transfer case isn't messed up, and spraying some "Liquid Wrench" or other penetrating oil on the linkage first is a better course of action. Let it sit, then try some of the persuasion suggested.

They do break and then you will have to buy the lever (competing with the DII owners) and do all the other work that you might have avoided.

Victor

 

[96DiscoSE7]

I'm not crazy about his order of operations.

I think beginning with crawling under, checking that the transfer case isn't messed up, and spraying some "Liquid Wrench" or other penetrating oil on the linkage first is a better course of action. Let it sit, then try some of the persuasion suggested.

They do break and then you will have to buy the lever (competing with the DII owners) and do all the other work that you might have avoided.

Victor

my truck CDL was stuck from non-use, would not budge, so this is the info to remove the shift unit and free it up.... works like a charm.... so whats your point?

 

[sven]

If I can lock the diff then can the solenoid be stuck?

Yup. The fact that you can lock and unlock the cdl makes me think that its most likely that solenoid inside the TC.

 

[steelheader]

My linkage acted seized a while back and it was the same, CDL fine, no low range. There is a neutral gear select activated solenoid on the top side of the transfer case. It had died (engaged of course) and I looked around for a replacement with no luck, so I ended up just sawing the pin off and sticking it back in there. I used the above link to work through it. It doesn't take that long to drill out the console and is quick work to seal up with a rivet gun. Once you can see everything it goes pretty quick, and is a lot less work than dropping anything.

 

[vabiro]

my truck CDL was stuck from non-use, would not budge, so this is the info to remove the shift unit and free it up.... works like a charm.... so whats your point?

My point is that it may work just fine, as long as it is not stuck so badly that using that much force would break it.:banghead:

Why not start off with some chemical warfare. It can only make things easier, and save you a lot of grief. Going straight to forcing just seems a bit ham handed.

I guess we differ on strategy

Cheers
Victor

 

[96DiscoSE7]

My point is that it may work just fine, as long as it is not stuck so badly that using that much force would break it.:banghead:

Why not start off with some chemical warfare. It can only make things easier, and save you a lot of grief. Going straight to forcing just seems a bit ham handed.

I guess we differ on strategy

Cheers
Victor

we do have the same strategy.... if you need to repair that is the web site that i used,
most people will not try the least invasive repair approach first.....I only used the website as the way to remove the unit and free it up on the bench vise BTW a socket on the end and tap the center link rod works pefectley to free it up, then lube the shit out of it.....