Thread: D1 Transfer lever stuck

You have to have a look at the linkages on the side and the top of the gearbox. If the exterior linkage to the difflock is ok, then take off the console, rubber boot and you can unbolt the aluminum housing. The spring clip for the pivot inside that housing can come off. All it needs is a clean, grease and re-assembly.

lots of spray lube on the linkages and then a very light drift and very light knockometer on the end linkage on top of the tcase foot while someone puts medium pressure on the lever in the cab.

When that doesnt work by itself lift up a front wheel and rotate it with the park brake on and the main box or t case in neutral while repeating.

once you get it free give it a good shooting with a lanolin spray and work it back and forth about 20 times.

Dont get over agressive if its an internal failure you'll just make it worse. If its internal you can, from memory fix it without dropping the tcase off.

You may have to do what I did.
Take out the centre console, remove the Hi/Lo Range/Diff lock lever assembly and free up the metal slide rod on top. Once you do it put lots of grease on it to stop rust, or it will do it again.

Cheers,
Ron

Look what I found in Common Threads--
http://www.aulro.com/afvb/common-thr...diff-lock.html