By Andrew Macris on Saturday, September 22, 2001 - 08:02 am: Edit

Hi there. I've read all the archives. I've attempted all known solutions. But my '96 Disco won't lock up anymore.

Here is a brief summary of what I have done...

• Confirmed lever is moving gear on top of transfer case (low works fine)

• I've sprayed a full can of PB Blaster up there.

• This morning (as Clint suggested) I backed up my
limit switch 2 full turns (it's about to come out)

With all this, no diff lock light on, and driving tests indicate no lock.

Does anyone know what I should try next?

Thanks,
Andrew Macris

By pjkbrit on Monday, September 24, 2001 - 03:48 am: Edit

Where is that limit switch located??????
Pete

By Andrew Macris on Monday, September 24, 2001 - 04:41 am: Edit

Pete, if you crawl underneath the vehicle with your head towards the front, it will be on the top of the transfer case on the back right section. You can see it with a flashlight. Though, if you want to loosen it, you will have to get at it with a wrench from the other side.

P.S. Come on guys (&gals)... don't let me stump you ;)

By pjkbrit on Monday, September 24, 2001 - 04:45 am: Edit

Thanks....and loosening it will do what?????
Pete

By Andrew Macris on Monday, September 24, 2001 - 05:40 am: Edit

From the transfer case manufacturer...

Q. The difflock on my LT230 does not engage even though the selector rod moves to the right position. Why?

A. Sometimes the difflock indicator switch sticks and this prevents the difflock selector mechanism moving across. Back off the switch one turn and try difflock again.

By pjkbrit on Wednesday, September 26, 2001 - 03:58 am: Edit

Cannot find the limit switch on my transfer box...and my selector wont budge left under any circumstances...anyone got pictures???
Pete

By Clint on Saturday, September 29, 2001 - 12:22 pm: Edit

pjkbrit,
If your lever won't move at all,
it is frozen up and needs a little TLC
on the underside with liquid wrench and a hammer.

Andrew,
have you had any further luck with the lock?
I think there is a spring in there which is between the short lever and the locking ring. The arrangement must be similar to manual locking hubs if you've ever taken those apart. The spring could be broken, but it is unlikely.

The only other sugestion I have is to temporarily remove the switch completely to make sure it is out of the way of the internal locking ring. Try moving the lever in and out. With the limit switch out, you may be able to poke around in there with a coat hangar to try and free the stuck locking ring.

Don't go through any water with the swith out.

Clint