CDL Strangeness

CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
My new to me Gen 1 Disco had a stuck CDL lever, even though the PO said the transfer case worked, I guess he was sorta correct. So I played with it a while from underneath squirting and testing. I eventually got it to move out of high and go into low range. Then I tried the same for locked but no go. He lived on a dirt road and it appears that it was never off road so I was not surprised that it was stuck from non-use. I tried every way I could think off to avoid removing the center console and drilling the rivets out but I ran out of options.

So I did all of that today and got everything exposed, tons of rust and sand and dirt caked in and messing up the works. I sprayed everything down and let it soak for a while. When I tried to move the lever to the left it still would not go. Then I looked in the gated area and noticed that it did not have much more room to move left. I tried to move it to the right and no budge. So I got a pry bar and started working it slowly and it moved.

It turns out I was stuck in diff lock and did not know it. No indicator on the dash or any other indicator. So, who knows how long it has been like that from the PO. I have only put a couple hundred miles on it so far, I really just started working on it.

Did I do any damage to anything? In the long run, it may not matter since I have ARBs and everything else to move over, and a spare xfer case if needed. I guess I need to get the DIff Lock indicator sorted out.
 

CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
I don't think it was in locked mode, I would have noticed the harder steering and slight wheel chatter. I have freed it up now and it works smoothly, I think the locked indicator is working too but I need to test it some more. I do have the issue where the lever will move side to side in the high range position now. It does not shift, the lever just moves. I can still shift everything using the usual procedure.
 

WaltNYC

Well-known member
Mar 3, 2010
450
8
NYC
You're confusing the heck out of me....

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I think the locked indicator is working too but I need to test it some more.
OK, so the light on the dash goes on when you push the lever to the left

I do have the issue where the lever will move side to side in the high range position now.
Issue? Not sure what you are describing. Does the lever move by itself? (pop out of gear?)

It does not shift, the lever just moves.
???

I can still shift everything using the usual procedure.
This seems to contradict the previous sentence
 

mgreenspan

Well-known member
Feb 28, 2005
4,445
26
Briggs's Back Yard
Ok. So you can always still move the CDL lever while the truck is moving. Are you saying the lever itself is loosey goosey? As in it wobbles easily? All the way left is locked. All the way right is unlocked. I assume when you have it to the right it sort of falls left slightly and then you can wiggle it easily, but you need to use more specific details or a video of what you mean. Is the lever going further right than is normally capable?
 

K-rover

Well-known member
Jan 15, 2010
2,006
19
Raleigh, NC
If I remember correctly, the lever has a clamp that goes over a long gear. If this is loose, the lever will move, but not engage diff lock. High and low would still work assuming nothing else is wrong.
 

CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
It is confusing. It is not that loose on its own. It will go into high and low range and lock in. It will go into diff lock hi and low range. It functions normally to do those functions. It is just that after it is engaged in whatever position I happen to have the lever, you can then move it side to side without changing the function of the lever. I can have it locked on hi range range normal and still slide the lever to the left and make it look like it is in diff lock hi range. The diff lock light might even come on, but driving it in that mode does not produce the effect of a locked diff. Yes the lever does seem to go more to the right than it should, past what would be the normal stopping point for the hi range non-locked position.

I will look into the LT230 docs that Walt has posted and see what I can find. The next step will be to open it up from the top that is now exposed as Dan has suggested to get a better view of the internals.
 

WaltNYC

Well-known member
Mar 3, 2010
450
8
NYC
Here is what it SHOULD look like from the top.

Based on your report that the light on the dash does illuminate it suggests you may have an internal issue. The beep in this video would be equivalent to the light on the dash. Also of note, the unit is 'upside down' in the video.
 
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CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
Not sure what the point of the 1st video is, I have had Discos for 20 years! I'm insulted... Unless it is for the newbies that might be following this thread.
The second video is not where I suspect the problem is.
Maybe you still don't get it so I will have to post my own video to show you.
 

Attachments

WaltNYC

Well-known member
Mar 3, 2010
450
8
NYC
not intended to insult....wasn't sure how long you have owned the truck.

" I can have it locked on hi range range normal and still slide the lever to the left and make it look like it is in diff lock hi range. "

The language is terribly confusing to me. There are five positions in reality....

Upper left = Locked + Low range -+-+-+-+-+-+-+-+-+-+-+ Upper right = Unlocked + Low range
Bottom left = Locked + Hi range -+-+-+-+-+-+-+-+-+-+-+-+ Bottom right = Unlocked + hi range (most normal driving)

middle = Neutral


It might make sense to break it into two questions.....
1. does your truck actually go into hi and lo range? rev range change would be obvious
2. does your truck actually lock the center diff? tire 'chatter' as you descibed
 
Last edited:

CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
This is the 99 with the problem, I have had it for 9 months. I have owned my 96 since 98 just to clear things up a bit.
It's an H gate, pretty easy to understand, I have an I gate. Flip the H on its side and you might get it. It still functions like the H gate should, but I have the additional annoyance of being able to move the lever WITHOUT changing the range gear that I am currently in. Video to follow for you in the next day or two. I am trying to get ready for our first big winter storm coming tonight. A 60 degree temp change in 24 hours. The weather here can be very moody here.

Answer to your questions; 1. yes now that I have freed up the levers and rods in the picture I just posted. 2. yes, now that I have freed up the levers and rods in the picture I just posted.

Do me a favor, go out to your vehicle and without moving the CDL lever toward the front or back, try to move it side to side and tell me what happens. You do not even need to start the vehicle, just try to move it side to side.
 

CORover

Well-known member
Jun 11, 2007
598
27
Colorado, USA
See this thread and pics for what is going on. He got there before me due to a heater matrix leak issue I need to fix first.