Seized Diff Lock

I hadn't noticed before but my diff lock on my 300tdi won't budge. It has probably never been used. Does anyone know an easy(ish) way to free it ?

loads of threads on this. In fact its what brought me here in the first place. Mine turned out to be a seized diff lock switch. The plunger in the switch was stuck and was preventing the mechanism going into place. The guy that does my servicing took 15 mins to fix by replacing it. However it could be something else. Its a good thing really because it means your disco hasnt seen much off road action. Have you tried going from the passenger side and giving it a good pull with both hands. Dont go mad or you'lll bend something. Get underneath and spray all the linkages with WD40. Its a common thing and chances are it'll be relatively inexpensive to fix.

Definitely worth doing a search on the site -there are loads of threads about this and there's a very useful external link which details this very problem.

Mine turned out to be the switch on top of the transfer box was stuck on one of the mounting bolts because somebody had reassembled it badly.

From what I've read, the most common cause is the sliding mechanism just underneath the selector stick rusts and causes it to stick.

You may need to take out the centre console and drill out the rivets on the rubber cover underneath but it's nothing tricky. You'll need a hand pop riveter to put it back properly but these are cheap and easy to use.

I'll give it a squirt of WD40 and try giving it a good pull from the other side. I like to try the easy things first!

Get underneath and find the bar that goes up to the transfer lever and give it a good spray at the top. While you're underneath, get someone to sit in the car and move the transfer lever left and right, you may be able to see what's stuck.

I am too used to a landrover with a big suspension lift! There is not much room under a discovery! I can't see how to get the gaiter on the transfer lever off? I prised it up a bit but could just feel foam on the inside.

I think you rotate the whole gaiter at the base 90 degrees and then just pull it up and unthread it.

The gaiters on the gear sticks come off by unclipping around the edges and then unscrewing the stick and gaiter until they come off. But you won't see much just by doing that because of all the sound insulation - to get a proper look you'll need to take out the centre console so you can lift out the insulation. And then you need to drill out the rivets on the rubber bit that's under that. It sounds like a lot of work but it's not and it's all easy stuff too (if I can do it almost anybody can).

It's worth trying the wd40 from underneath first tho'!

I wouldnt take the console out just yet!

Well I WD40'd everywhere and it still wont budge! I even took the stick off and cut out the soundproofing and quirted WD40 in the top but still no luck.

ps I did put the "bits" of soundproofing back!
Tom.