So I did some digging, and it looks like the lever housing was seized. I wrestled with it for a while and got it a little bit loose with some pb blaster and hammering (if you use a hammer, PLEASE be careful hammering the eyelets, they can break.) I got it all installed again, and problem solved...
I haven't done it since I bought it last year, but the fluid was checked and seemed to be just fine. So I haven't bothered yet.
@Mark W
That's what I think is going on. I'll try to use some penetrating oil first before I remove it and attempt a full cleaning. This has actually been a relief...
>> Hmm, so in the past it's worked just fine for you without much pressure so that's a good sign that it's been used and works OK. But then it gradually got tougher and tougher to the point where now you're thinking it just takes too much force to shift right?
-- Yeah, that's right. I'm...
I have a 2001 LC100, 270k.
Up until the past few months, the transfer case was relatively easy to shift in and out of. But as of recently, the lever has needed more and more pressure to engage 4hi or 4lo, even going into N. I was able to engage it a couple weeks ago on a steep climb, but...
I took this off and built my own rack, need it gone. Nothing is cracked, all seals were pretty solid. No damage was done removing the rack. It also includes all 8 mounting screws. Willing to part out, but would rather sell all together.
Update:
End caps sold
Bolts sold
End cap rubber bushings...