Chris;
I've had a 1993 Tdi with manual main box since new. My transfer box always felt spongy but worked OK so I thought that was normal for a Disco until....at about 100 00km or 7 years later it first started to jump out of high and later I could not select high. It cost $A400.00 to have a look at it and the verdict was that a clamping screw on the high-low selection fork had fallen out to the bottom of the case and luckily did no damage to any gears. Repairs cost nearly $A2000.00 and the transfer box feels entirely different now. Positive end stops and free movement in between. I must add that I use low range every day to reverse up our steep drive way but still this shouldn't have happened. Just another of
37 defects that the Disco has racked up. Frank in Aussieland ............................................................ ............................................................ ..................