Transfer Case Struck in 4 High

Zeus

Active member
Oct 6, 2004
31
0
Ellicott City MD
:eek: I have a 98 Disco and I my shifter is stuck in 4 High. It will slide to Neutral and 4 Low but not to 2 High or 2 Low. I have pushed on the shifter in Drive, Neutral, Reverse, Stopped, Rolling down a hill. Nothin. Any ideas?
 

Zeus

Active member
Oct 6, 2004
31
0
Ellicott City MD
To rephrase I am stuck in locked diff high, and need to get to unlocked diff high.
Try as I might I can't get the shifter to slide to the right.
I have owned the truck since it is new and have never had a problem.
 

p m

Administrator
Staff member
Apr 19, 2004
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La Jolla, CA
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Don't force it. You can get down under the truck, grab a large screwdriver or a lug wrench, and unlock the center diff.
Short of taking off the center console, you can try to lift the T-case boot, and using a syringe with a fat needle (or if you're lucky, a straw from a WD40 bottle), and douse the shifter mechanism with penetrating lubricant.
If you force it, you can break the plastic collar that keeps the shifter centered. Ask me how I know...
 

pan2sa

Well-known member
Oct 5, 2006
190
0
San Antonio, Texas
p m said:
If you force it, you can break the plastic collar that keeps the shifter centered. Ask me how I know...

Haha, I'm glad I'm not the only one...just did that last week after buying my D1.. Now I'll have to tear all that shit apart to fix what I broke. For now, it stays that way though.
 

squirt

Well-known member
Nov 13, 2008
824
13
Los Angeles
Agree about not forcing it... It's also possible to bend the linkage. Climb under and manually move the lock tab.
 

p m

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Apr 19, 2004
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pan2sa said:
Haha, I'm glad I'm not the only one...just did that last week after buying my D1.. Now I'll have to tear all that shit apart to fix what I broke. For now, it stays that way though.
Let me know if you need help fixing that.
I was surprised that not too many people run into this problem, given the complete lack of protection of the shifter housing against dirt/water ingress.
 

pan2sa

Well-known member
Oct 5, 2006
190
0
San Antonio, Texas
Best thing to do is take the console out and use penetrating oil, work it slowly, re oil, work it some more, re oil.....keep going until it frees up, once its functioning correctly, mummify it with grease. And then make sure to use it every so often so that it continues to stay free and functioning..
 

vanwyk4257

Well-known member
Sep 19, 2009
52
0
Grand Rapids, Michigan
It's an easy fix if you pull the console remove the shifter to free up the rod, lube the heck out of it and put it back in. I had the same problem on mine when I got it. I packed a boatload of good synthetic grease in the housing so it would lube the shaft and other bits every time I use it so it doesn't bind up again in the future. I actually removed the shifter assembly from the truck and soaked it in simple green degreaser. Mine was stuck badly enough that I had to use a dead blow hammer and a block of wood. After tapping it back and forth a few times, cleaning it with emery cloth and lubing it with grease it moves very smoothly now.
 

p m

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Staff member
Apr 19, 2004
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La Jolla, CA
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Funny thing is that a sticky t-case lever is commonly attributed to the lack of use. Well, mine definitely did not suffer from the lack of use, neither there's mud to pack up the housing. And yet it did gunk up.
 

EJB90

Well-known member
Feb 26, 2007
1,231
0
33
Connecticut
Try some WD-40 and such on the linkage. Freed mine up after a few treatments and some finagling.

Once loosened up every so often when on an appropriate surface lock and unlock the diff to prevent it from freezing.