Right here we go.....
Derek, yep i've tried soaking with all sorts of oils and it still wont budge. Put it back on the car as i need to use it soon.
Quote from Dougal:
"You now have a 'working' high/low setup by which I presume the lever moves backwards and forwards H-N-L (before you disconnected the linkage etc.). Have you actually driven with high/low gears to verify that they are engaging or are we only talking about movement of the gear lever?"
Yes the H-N-L bit works ok. Have driven with it in L and all is well.
Dougal again:
"I don't understand what you have on the bench. Is this the high/low selector shaft assembly? The housing in which the selector shaft moves fits on the top of the front output shaft housing, has its long length across the vehicle and is held down with six bolts. The selector shaft will rotate in its housing only. It does not pull in/out."
I think i know what bit you are on about and no it aint this bit that was on my bench. All of what you describe above seems to move freely enough. As Lee said "On My Disco that same lever moves sideways to eng the Diff lock with H-N-L". What i had on my bench was the actual lever assembly that sits on top of the transfer box. Its held down with 4 M8 bolts. Consists of a ali housing, a shaft that runs left to right (=A354 new, apparently!!!), in this shaft is a ball joint that takes the actual gear lever bit. Attahced to the bottom of the lever shaft is a spline thingy which does the H-N-L bit. The problem bit is the bearing assembly at the passenger side of the ali housing. The left to right shaft runs in this and allows the lever to move to the left to engage diff lock. This bearing thingy is seized solid to the shaft, hence no movement left to right.
Anyone understand that?!. Oh nearly forgot the new bearing bit is =A315.
Dom J