Stuck Diff lock lever HELP!!

[Lino]

Yes it was stuck before but i always managed to get it unstuck. This time the lever broke off. What can i do to repair it. Do I have to lower the transfer case?? And how do i get it unstuck, it's stuck on diff lock in high. It will transfer to high and low but won't go left and right. But with the lever cracked off i think i am in big trouble.

Thanks
Lino

 

[DeanBrown3D]

Where did it snap?

 

[Monty]

You'll need to pull the console out and remove the dust boot from the shifter. Unbolt the top plate around the shifter, remove the shift linkages and pull up the shifter from the mounts. From there, you can also reach the linkage going to the diff lock bolt and turn it to unlock the t-case. Replace what broke and re-assemble. HTH

BTW, here's the site I used to help me with fixing my stuck cdl.
http://home.twcny.rr.com/eeibooks/rover/discodifflock.htm

 

[Lino]

It looks like i snapped off 3 inches of it. Once i i rmove council and try to get unstuck, would i be better off to weld it ( if i could be done) or just replacing the part.
If i have to replace the part is it hard to take apart that lever contraption?
By the way thanks Monty for your site, it will come in handy.

Lino

 

[Monty]

Thats not my site Lino. That was the site I used as a reference to free up my stuck shifter. I think I would try to replace the shifter assembly as a whole, rather than weld the shifter bolt back on. The assembly was pretty easy to take out but is a little time consuming, although not too bad.

Even if you decide to keep your broken shifter and weld it, you'll need to pull the assembly from the truck and follow the directions on that link to free it up. It seemed hopeless trying to shift to lock by hand but a few light blows from a hammer worked. If you get a new assembly, make sure it shifts correctly before installing it in your truck. Good luck!

 

[Makwa]

Stuck Diff Lock Lever

I just finished doing that on my 95 Disco 2 weeks ago. It took about an hour to get it totally apart, cleaned up, relubed and back together.
Once you pull the console you have to drill out the rivets, then pull all the boots off. This gives yu access the the shifter. Spray everything liberally with WD40 or some similar type fluid. Particularly the points, on the bar that goes down from the shifter to the transfer cases, where they are joined to the shifter. These can be really prone to rusting and seizing. Spray lots and lots. That was the advice given me. This helps free everything up so you will not break the shifter in the future.
Next remove the bolts from the top of the casing where the shifting lever is. From here you can totally disassemble the shifter, clean it up and relub it before reassmbling it.
I was told to use white lithium grease on the shifter parts to keep it going and to make sure that at least once per month use the diff lock, etc. to keep it in good working order.

Brian

 

[Lino]

Thanks for all the help. I got one more question. Can I buy the shifter only or do i have to buy allthe assembly.

Lino