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Arbman Al



Member Since: 04 Jan 2012
Location: Surrey
Posts: 80
Hi/lo lever jammed?
I have been busy converting my 130 from 300tdi to TD5 and also from manual R380 to ZF4 auto.

The ZF4 came from a Disco 1, and I also have changed to a Disco transfer box from a manual (i think, part no. STC8959e)

When the transfer box was seperate from the auto box the hi/lo and diff lock levers worked fine, now that everything is together I was putting on the hi/lo and diff lock linkages and could not get the hi/lo to move at all, diff lock is ok. Took the linkage off again and put some mole grips onto the hi/lo lever and it won't budge using a reasonable amount of force (don't want to overdo it and break something)

What's happened?

Confused.....Al 1996 Defender 130 converted to TD5 and auto

1975 Triumph Stag 3.0 V8
Post #114753 12th Jan 2012 8:47pm
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walfy



Member Since: 29 Aug 2007
Location: Frome
Posts: 2658
 
Using mole grips you'll have to use a fir amount of force to engage. If you look at the length of the levers and where the fulcrum is you'll realise how much force you need.

It does become a bit of trial and error when refitting the levers if you haven't marked them before removal. Keep at it and you'll soon realise which way round it all goes Thumbs Up 110 D250 SE HT
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Post #114782 12th Jan 2012 9:44pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006
 2011 Defender 110 Puma 2.4 USW Stornoway Grey
auto box is not in Park is it?

handbrake on with difflock in? Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop
Post #114785 12th Jan 2012 9:51pm
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Arbman Al



Member Since: 04 Jan 2012
Location: Surrey
Posts: 80
walfy wrote:
Using mole grips you'll have to use a fir amount of force to engage. If you look at the length of the levers and where the fulcrum is you'll realise how much force you need.

It does become a bit of trial and error when refitting the levers if you haven't marked them before removal. Keep at it and you'll soon realise which way round it all goes Thumbs Up


Before t/box, gearbox and engine were joined, the lever moved easily with mole grips. I'm thinking it's just cogs not lining up?
Engine is not startable yet, so may have to come back to this. 1996 Defender 130 converted to TD5 and auto

1975 Triumph Stag 3.0 V8
Post #114793 12th Jan 2012 10:05pm
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Arbman Al



Member Since: 04 Jan 2012
Location: Surrey
Posts: 80
jst wrote:
auto box is not in Park is it?

handbrake on with difflock in?


Why would auto being in park make a difference?

I can't start engine yet as ecu has to be matched with injectors etc. 1996 Defender 130 converted to TD5 and auto

1975 Triumph Stag 3.0 V8
Post #114794 12th Jan 2012 10:08pm
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Defender SVX



Member Since: 29 Jan 2009
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United Kingdom 2008 Defender 90 Puma 2.4 SVX Soft Top Santorini Black
My 50th auto had to be in neutral to move the hi/lo lever. Thumbs Up Formerly mao99999
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Post #114836 13th Jan 2012 7:49am
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walfy



Member Since: 29 Aug 2007
Location: Frome
Posts: 2658
 
Same on my 300 Auto, has to be in N to move hi/Lo lever 110 D250 SE HT
110 USW SOLD
RRE HSE Dynamic Gone, wife killed it
VOLVO XC60 R Dynamic with some toys

Polaris RZR 900XP SOLD
Post #114864 13th Jan 2012 9:16am
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Arbman Al



Member Since: 04 Jan 2012
Location: Surrey
Posts: 80
I haven't got the electrics wired up yet.

Problem was the bolt going through from the front holding the t/box to the g/box near the hi/lo lever was too long and fouling the gears inside!
Had not realised one bolt was shorter than the others.

Could have been nasty if I had tried to drive it to free it off.... 1996 Defender 130 converted to TD5 and auto

1975 Triumph Stag 3.0 V8
Post #114961 13th Jan 2012 12:56pm
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jst



Member Since: 14 Jan 2008
Location: Taunton
Posts: 8006
 2011 Defender 110 Puma 2.4 USW Stornoway Grey
Arbman Al wrote:
jst wrote:
auto box is not in Park is it?

handbrake on with difflock in?


Why would auto being in park make a difference?

I can't start engine yet as ecu has to be matched with injectors etc.


i was only trying to help

you take them out of park to help with gear alignment rather than having it locked in one place. Cheers

James
110 2012 XS Utility
130 2011 M57 bespoke Camper
90 2010 Hardtop
90 M57 1988 Hardtop
Post #115213 13th Jan 2012 10:22pm
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