Real time: transfer stuck?

[Texx]

In 4 Hi, apparently been that way for some time, hubs not locked. I'm suspecting corrosion in the linkage, is it as easy as pulling the piston off the passenger side of the transfer case and cleaning it up?

 

[Poser]

Yep, it really is that easy, and very well could be the reason.

The pivot for the transfer case shifter linkage on the side of the transmission also corrodes creating difficult shifting as well. It should have a grease fitting on it; make sure it takes grease and is free there as well.

 

[Texx]

So, I assume there's more to it than removing the four bolts that hold the piston to the transfer? Did that, but not loose yet.

 

[DallasFJ40]

I had the same problem. Once it was off, I had to beat the heck out of it to free it up. BTW, there is a spring and detent ball in there (mine flew out and was lost when I took it off).

 

[Texx]

Thanks guys, that did it. It was a combination of the two. Here's a pic of "barnacle bill" about an hour ago!