Can the transfer case solenoid be repaired or just tossed?
#11
Once the driveshaft is out of the way you just use a manual impact driver to remove the #3 phillips head bolt that keeps the drum in place, then the main drum cover will slide off. The backplate is held onto the TC with 4 15mm bolts. After that you can move the assembly out of the way or go one step further and remove the clip on the ebrake handle & sit the assembly out of the way totally. I’ve done it either way.
#12
#13
It’s a solenoid & they either burn up, or get stuck. I personally have removed the unit from my 02 Kalahari, (was stuck in 4Hi when I bought it), so I made a blank plate for it, and sealed it up with some black RTV. Then I installed an 04 CDL Linkage and just simply plugged it in (03-04 interlock is not on the TC anymore. It’s mounted on the 4Hi/N/4Lo linkage instead. So if you can get a hold of an 03-04 unit (03 if you don’t have a CDL & 04 if you do) it’s a PNP upgrade vs the older setup & much easier to work on in the future.
#14
The main reason a RRC/D1/D2 have the interlock solenoid is to prevent it being activated while the vehicle is moving. All it takes is one purse strap or say an iPhone cord to pop that lever into something else besides whatever is selected. It could cause the TC to explode into pieces internally, or worse it could cause an accident.
Bypassing it on the TC, and installing an 03-04 Interlock setup is the best bet. Much easier to service, and no chance of it being moved by even the smallest mistake inside the cabin.
My 97 XD has it bypassed/removed (was done before I bought it) and I've already bumped it once myself while I was sitting inside of it working on the radio. I was totally unaware I'd even bumped it, but when I went to move it I was in N. The 4Hi/N/4Lo on my XD is extremely easy to move and I plan on fixing the Solenoid whenever I get a chance. I should be able to modify an 03-04 D2 setup to work on the D1. I'll just have to make a plate to hold it.
Bypassing it on the TC, and installing an 03-04 Interlock setup is the best bet. Much easier to service, and no chance of it being moved by even the smallest mistake inside the cabin.
My 97 XD has it bypassed/removed (was done before I bought it) and I've already bumped it once myself while I was sitting inside of it working on the radio. I was totally unaware I'd even bumped it, but when I went to move it I was in N. The 4Hi/N/4Lo on my XD is extremely easy to move and I plan on fixing the Solenoid whenever I get a chance. I should be able to modify an 03-04 D2 setup to work on the D1. I'll just have to make a plate to hold it.
#15
Ah, while driving, yes that wouldn't be so great. Though I'd hope to get lucky and just hit Neutral, yikes though!
I've an 04 so I suppose my situation is a little different. I suppose I could grab a 9v battery and connect it to temporarily get to neutral yes, or 12v if that wasn't enough power to activate it. Would you be able to speculate on what wires would be easiest to hit?
I've an 04 so I suppose my situation is a little different. I suppose I could grab a 9v battery and connect it to temporarily get to neutral yes, or 12v if that wasn't enough power to activate it. Would you be able to speculate on what wires would be easiest to hit?
#16
Yeah with an 04 just get a hold of any 03-04 linkage & remove the solenoid. It’s held in place by a c-clip so replacement isn’t that bad. Should be able to get to it from the inside with just the center console out & black shifter plate. MUCH easier vs 94-02 with the interlock solenoid mounted on the TC.
#18
#19
Yeah with an 04 just get a hold of any 03-04 linkage & remove the solenoid. It’s held in place by a c-clip so replacement isn’t that bad. Should be able to get to it from the inside with just the center console out & black shifter plate. MUCH easier vs 94-02 with the interlock solenoid mounted on the TC.
Thread
Thread Starter
Forum
Replies
Last Post