Rick- In hi range 4 wd selection relies upon a spring moving the selector
into place. Typically on vehicles that do not have 4 wd engaged very
often, the shaft sticks in the aluminium housing (there is no bearing
bush). The area gets wet and corrosion of the steel shaft and the
aluminium housing occurs.
To remedy the problem, remove the floor to gain access to the front of
the gearbox at the front output area. Remove the nut from the end of the
hi low selector shaft, remove the 4 wd selector assembly, this will then
permit the removal of a sheet metal cover that covers the end of the 4 wd
selector. With the shaft exposed use liberal amounts of WD40 or similar
to lubricate the shaft so that it can move in and out easily under the
load from the internal spring. If necessary polish off the rust on the
shaft end, apply some anti seize grease and move the shaft a few times so
the grease gets inside the hole. Apply some more grease and replace the
cover and the shafts.
Regards
Bill Leacock
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