Disco 2 CDL - Stiff

Used the CDL on the weekend, all good, but the selector is very stiff and clunky? Does that mean the transfer box is possibly low on oil? Is there a technique you use to get smooth and clean changes from Hi to Lo to diff lock?

Most likely the selector at the base of the lever is stiff through lack of use.
Very common fault.
you can try changing the fluid but I doubt much it'll be that.
Quite easy to check if it is low and top it up.
To sort it you take the centre console out, drill through the pop rivets, remove the unit on top of the gearbox and take it out then give it a proper freeing off and lube it.
However since it does move, it might be enough to give it a good working to and fro, left to right, from time to time.
By far the biggest pain in the whole job is putting new pop rivets in where you took them out from, the rest is pretty easy.
Of course others use other forms of fastners.
Technique for use is in the handbook.
Doing it on the move needs practice after all there is no syncro on it!
Best of luck.

We had a reconditioned transfer box installed recently and it was incredibly difficult to move between high and low range (t was fine with the old box) , and to engage the diff lock. With use the diff lock freed up but whilst hi/lo got better it was still an effort. As @Stanleysteamer says we started to use the 'on the move' technique detailed in the handbook and it is much easier but needs practice.

Lever gets stuck, small amount of oil MAY free it off under the cover

Thanks for the feedback - might try the "on the move" method then! Seems like it is normally a bit stiff then - I do get it to move, but I just wondered if it was normal for it to be stubborn? Transfer box fill level is fine.

Mine has been stiff for 2 years at least,as SS said above .With use it has got better,oil lube made no difference to mine.
But using it does ease , probably need to put a post it note on the dash to remind me to do it,I just forget.

I took mine out to find out it just needed cleaning and lubrication

on my previous D2 it was also very stiff. To move it the first time was a real fight, but after it got better and better. If the selector cable is out of use for long time it gets dry and will stick.
regarding on oil level in the Tbox, I think no connection....

MJI said:

I took mine out to find out it just needed cleaning and lubrication

Click to expand...

Easy to do? Described in RAVE?