Hi my dad and I are trying to get the Disco ready for a trip on Sunday and are trying to remove the solenoid from the T-Case and can’t get one bolt out closest to the passenger side front tire. Any suggestions??? All help is appreciated!!
Thanks
TyTyBinks

 

That cable in the pic is going to be in your way. It has a mount which secures it to the body of the TC. It's on the top about mid way and it's a 10mm bolt. Whenever your messing with the Interlock solenoid and the 10mm bolt that secures the cable to the case (just a support for the cable) I highly recommend having the E-Brake Drum assembly removed as it makes things MUCH easier. Once you remove that 10mm bolt which holds the cable down you can then push up on the cable and get enough room to gain access to all 4 bolts which secure the Interlock Solenoid body in place. I personally would ditch the Interlock solenoid on the TC and if you don't have CDL use an 03 H/N/L selector/cable as the interlock solenoid is moved up onto that piece vs the TC. If you've got a CDL nipple and you are going to use the 04 selector/cable setup then the solenoid on the assembly can be used and it plugs in identical to the 94-02 unit's plug.

Once you get your old unit out I would take a thin plate of steel (I used an old metal shim I had laying around which was probably 1/8 thick. I drew an outline of the original housing, drilled the 4 bolt holes, slapped some RTV on it, and installed it in place of the old Interlock Solenoid body (I was going to an 04 Linkage as I had the CDL nipple), it makes re-installing those 4 bolts a breeze and it will be much better sealed vs trying to seal off the OEM housing (especially where the OEM wires would have ran out if you totally gut it). You'd also need 4 shorter bolts as the plate is thinner vs the OEM Interlock Solenoid housing.

 

Thanks a ton! I will be going to the junkyard tomorrow morning to see if the 03 there has the cable still. I do have the CDL nipple and I will try to install it tomorrow. Any idea on what the ideal thickness plate is for the solenoid as I don’t have any spare sheet metal lying around? My dad is taking me on one of the land rover experience trips for my birthday literally 48 hours after finishing the head gaskets, so wish us luck (especially since we are going to 5.5 hours away!)
Thanks Again
TyTyBinks

 

3-5mm thick plate would work. I'd almost say you could get away with a J box cover plate for a duplex, and then just cut it out to match the OEM housing shape. As long as you use RTV, and shorter screws so it can tighten down I'd think that would work. I just had the 1/8 thick plate laying around so I used what I had.

Since you have the CDL you will want to find an 04 linkage so you can use the CDL on your TC (03 did not have CDL). I'd also grab the SLABS unit from the 03-04 (03 in foreign markets had CDL) so you can just swap it out and gain 04 CDL functions. Not a deal breaker but you'll want a SLABS unit out of a vehicle with the same rear suspension setup as yours = Coil or SLS. If it's not the same you can of coarse program it via a Nanocom unit.

 

Also how did you get out the cable mount? I can’t seem to reach it from the center console.
Thanks

 

Nevermind I got it out with a long 3/8 extension and a universal socket