| Author | Message | ||
     Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 14 Registered: 06-2003 |
OK here we go... 1995 Disco...My CDL cross shaft was seized...I went through the other CDL posts and gathered all the info I needed (Awesome ammount of info!) to rebuild..When I removed the linkage and tested the diff lock ...IT WORKS!! whew... (the light came on initially but has not come on since.) I kept testing it (with the wheel off the ground) and it still worked even though the light did not (so I assume the light is kaput?)... OK...heres problem #1 (refer to pic below) I broke the small plastic peice which fits into the hole in the cross shaft and holds the ball on the gear lever in position and the spring compressed. It has a C-clip retainer on the bottom and an O-ring on top. For now I pulled a fast one and Krazy Glued the peice back together!! Hey don't laugh...its working!! I've tested it out pretty good too... But of course I want to replace it!! BUT I can't figure out how a new one could even be replaced as I can't figure out how to get the top of it (see pic) off the gear lever?? ...Hope this all makes some sense?!?!?  | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 15 Registered: 06-2003 |
On to my second problem... After all the hammering, greasing, twisting, prying, glueing, testing and finally reassembling.. I couldn't get the diff lock off!?! It seemed the lever was not pushing the diff bar far enuf to the right to unlock?? For the life of me I can't figure it out?? It works great going into four low and high? So I disconnected the pin that connects the cross shaft to the diff bar lever (thingy?) and slid a bolt between the end of the shaft and the lever (see pic) ...I then moved the gear shifter right and it worked (the diff was unlocked) But of course when I tried to put it into lock again it pulled the shaft out of the lever. I used a peice of wire through where the pin should be...Its working ...and very nice and smooth tooo..But what the heck happen?!?! I'm sure I did not bend the levers. Is there a way to adjust it???  | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 16 Registered: 06-2003 |
This picture is just to show how if I put the plate you see me holding back on it restricts the gear shifter from moving far enuf left to engage...(due to my make shift spacer)  | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 17 Registered: 06-2003 |
ONE MORE!! I thought I'd just include this to show how far the cross shafts moves left. This is the movement which was seized. I had to put this in a vice and pound on it. I had a peice of hardwood to pound on at first but ended up having to go metal on metal and finnally movement. Once it started ..I just kept lubing and twisting and sliding until it felt right... I had to file the end I pounded on after to fit in the diff lever, because of the severe beating I gave it!! ...  | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 18 Registered: 06-2003 |
So finnally after having to read all that... I need that plastic peice and possible a tip on how it goes on?? The part number and name does not show in any of the diagrams posted in other posts (I could be wrong though)... Is there a way to adjust the diff lever so I don't have to use that make shift bolt spacer.. THANKS FOR ANY HELP AND EFFORT ...IN ADVANCE!! | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 19 Registered: 06-2003 |
Well just got back from the local pit...and things work great...I might try to bullet proof my make shift solution, leave the plate off and just put everything back together as it is.•••••• suggestions??? | ||
| Graeme Day (Graemeday) New Member Username: Graemeday Post Number: 5 Registered: 02-2003 |
Hope your problems are now fixed; FWIW I have developed the habit of shifting low range to high range and operating difflock before I shut down for the final time each day. May sound excessive, but I suppose it's a bit like the human body. If you don't use it, you'll lose it. | ||
| Zach Jaggers (Mountenn) Senior Member Username: Mountenn Post Number: 280 Registered: 03-2003 |
appendix? | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 20 Registered: 06-2003 |
Well the diff lock works but the problem of the adjustment still bothers me. I really like to get a pin in there and have it work the way it should! I'm sure when I really need the diff lock that wire I used will break.. Anyone? Can I adjust ?? | ||
| Peter Sharratt (Gummikuh) Member Username: Gummikuh Post Number: 146 Registered: 02-2003 |
Hi Phil Is your truck auto or manual? This is exactly what I have come across in the past, everyone goes on about crawling underneath and spraying it! HAHA. When a customer wants it fixed, they usually want it done same day! I have had a look for this part and the best I can come up with is a replacement stick complete. There are 3 different sticks listed so I would suggest you take it down to a LR computer and get the right one. They are not that expensive, here in the UK Worst case is about £25. Part numbers are: FTC2471 bent stick FTC4735 rubber mounted FRC9674 straight There should be enough movement crossways with the top plate on, if not something is wrong, it may require freeing up a bit more. You really need that top cover to keep all the crud from going into the housing. When you reconstruct your console, you will squash your fingers each time, without the top plate! Best of luck Pete S | ||
| Phil (Discoanywhere) New Member Username: Discoanywhere Post Number: 25 Registered: 06-2003 |
My truck is an automatic. I'm 99% positive the cross shaft is completely free. I took it apart again and made sure. In the last pic above (which shows the cross shaft to the far left position) ...If i move the shaft right (which would be diff unlocked)It moves until the left end of the shaft is flush with the case the shaft slides in. (Hope this makes sense) anyway I assume this is as far right as the shaft will move ?? Which is my problem!! Its not enuf to unlock the diff? I'm going to the dealer today and try to drag a mechanic out to look and get me the right parts I hope that does it.... PS!! The parts listed above ...bent stick/rubber mount/straight... Does anyone know how to get these parts apart?? | ||
| Peter Sharratt (Gummikuh) Member Username: Gummikuh Post Number: 147 Registered: 02-2003 |
Hi Phil The parts computer is listing these as one item number. This would suggest to me they don`t come apart,(unless you break it) I would bet the big metal collar is put on before the stick is bent, therefore you may need to buy the whole stick. Best of luck Pete S |
