So I ended up removing the solenoid from the TC, but rather than fabricate a replacement plate, I just removed the entire solenoid and replaced the metal solenoid housing, just without the solenoid in it. Seems to work fine so far. Any glaring oversight on my part? I RTV'd and all.

 

Nope that works fine as long as it’s sealed up really really good. I just made a flat plate because I had it laying around.

 

With my motor and harness out, I have no way to move this vehicle easily. You'd be more the expert than I on this, do you think my best option is to remove it so I can go to Neutral on the T-case and be able to move it around? I only have one kiddo and he's 8 and very aware of mechanical workings so he can be instructed not to shift to Neutral ever for dangerous reasons when parked at a grocery store etc. I don't see any other drawback besides risk of theft.

 

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.

 

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?

 

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.

 

I'll have a look, thanks again!

 

no problem at all

 

I used two metal brackets and a quick release pin. It goes nicely with my CDL shifter that looks like a rocket arming switch.