High Low selector lever

I have a defender 110 with a disco 1 engine, gearbox, transfer, etc.

Everything on the car has been running great but I've been having issues with selecting low range.

It has selected before and I've driven in low over a few things, but the last time I was out driving steep gravel it was difficult to get it into low, and if it would go in, it would pop out while driving.

I have been looking around the transfer box from top and bottom. It's all greesed and nothing seems to be wrong here, the levers are all linked up fine and diff lock selects without an issue.

The trouble seems to be the 'selector rod' that comes out of the high / low case with the lever on it, that the linkadge then attaches to hits the metal case of the gear box when trying to move fully back to select low range. Is this common? Has the selector rod or the lever slipped slightly and now I am having to push too far to select low?

If this is the case I'm guess I will have to drop out the unit and check the selector rod inside the case for wear.

Many thanks

Sounds like the internals of the lever mechanism need some work. There is a thread on how to take it apart. It is quite easy as I managed to do mine!!! There is a detailed thread on this, search for high low lever stuck.

Just wanted to update and put this one to bed.

I had to do a few things,

1. The pin that links the first rod to the second (going from the top downwards) lost it's split pin and had come half out, jamming against the case.
2. The linkages had to be tighten up with a hand from under neither and someone in the car pushing and pulling.
3. finally (and amazingly) I had to take a pair of metal shears to the metal floor that the selector was pushing up agains and take about 5mm off making a slightly larger hole.

Now she works like dream.

Final update for anyone having this issue... as I've been dealing with it for a while.

These are things I've done under other peoples advice. Should have followed this advice from day one, but there you go... Just glad the thing works now.

Step 1: check the linkage is clear and working. Take off the rudder boot around the lever and have a look down inside, a bit of spray from on-top (or under if you can see what you're spraying) and it might clear.

Step 2: Check linkage range. There are two 13mm nuts on the high low lever that can be adjusted to find the right balance between getting the gear all the way into high and into low. You can also slide the linkage off the gear that comes from the drivers 'high-low' lever. This slides off and then you can move it a few teeth one way or another. BUT ask yourself honestly if you really think you need to do this, as it's unlikely to have slipped on it, and it can be a bugger to find the original position again.

Step 3: Bushes. Where the link joins the different parts together there are two little bushes (FRC4499) that make the whole system snug. These can brake and fall out, leaving slack in the system. Maybe one missing won't be an issue. I was missing all of them, leaving a lot of play.

Step 4: High Low finger allen screw. The high low cross shaft housing (on the passengers side of the LT230) is secured by 6 bolts and has the breather bolted to the top of it. You will need to remove the linkage to remove it. Inside the cross shaft attaches to a finger that pushes the something to select the high or low gears. This allen screw should be tightened. It makes sure the full movement of the drivers lever goes to the selector for the gears.

Step 5: Select the correct transfer gear, and very gently allow the clutch to come up while keeping pressure on the lever , you may feel the lever travel the last distance over the gears as everything gets perfectly aligned.

Step 6: if you still need more range to get the damn thing to find low range you can remove the metal collor under the high low drivers lever gaiter and file down the inside edge. This gives you a bit more push.


Hope this saves someone some time. it really should shift easily and find it's home and not pop out. Wish I'd have lightened that bloody allen screw when someone first suggested it!