This is only available on a suffix C or later (last number of transfer case), it cannot be changed on Suffix A or B transfer boxes. On a 1.667 or a 1.410 removal of the gear is simple, it just slides out; on a 1.222 it in necessary to rotate the intermediate gear to a position where the teeth on the middle and rear gears are in line and allow the input gear to slide through. It is not possible to change a 1.003 in situ.

Some "pattern" gears are not "crowned" during manufacture and will whine because of the edge contact this creates

Sometimes the difflock indicator switch sticks and this prevents the difflock selector mechanism moving across. Back off the switch one turn and try difflock again.

Check that the bolts you used to bolt the transfer box to the main box are in the correct positions. It is possible to fit a "longer" bolt in a position which will jam the intermediate gear and prevent it rotating. There are three bolts down each side attaching the transfer box to the main box and it is the middle of the three on the right hand side that causes the problem. On earlier transfer boxes a "stud" was fitted in this position to reduce the possibility of error. Sometimes the stud is omitted on later boxes or rebuilds.

The most common error when setting the difflock is not understanding which position to set the input shaft to. As you noticed there are three positions on the difflock input shaft; counterclockwise, centre and clockwise. The counterclockwise position is a "dummy" i.e. not used. You need to set the linkage up to move from centre position to clockwise position. If you set this up to this position you should resolve your problem.

We make a “High Ratio Transfer Case Kit”. This has the effect of permanently raising high range by 32% and leaves low range ratio unchanged. This is as strong and quiet as the original, cost effective and can be used with the PTO. It does not necessitate the re-calibration of the Speedo. We are only able to supply this in kit form.