Removing transfer case solenoid

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
New to me 96 Disco has shifting issues.

Anyone have a picture/drawing of where exactly this is and the best method of removal (from the top/from the bottom)?


Thanks
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
I have the hi/lo/lock shifter section opened up, do I need to remove the rivets/plate for the transmission shifter also to get to the solenoid?
 

benlittle

Well-known member
Jul 18, 2005
4,086
7
Draper
ptschram said:
I don't see how it could be accessed from beneath without removing the mounts and lowering it.

I did it this way. It's quite easy, actually. It does take a bit of contorting but it can be done.

PT is right, it's secured with 4 8mm bolts. If you reach from the left side of the drum, you'll feel the solenoid. The bolts are in about a 2x2 square and the solenoid top is round and protrudes about 1in above the base of the 4 bolts.

I removed the cap/ solenoid.

Removed the solenoid.

Cleaned surfaces.

Apply RTV.

Replace cap without solenoid.
 

benlittle

Well-known member
Jul 18, 2005
4,086
7
Draper
Jay5oh said:
I have the hi/lo/lock shifter section opened up, do I need to remove the rivets/plate for the transmission shifter also to get to the solenoid?


WOW, I wish I had found this earlier. That way is WAY harder than doing it from below!!!!!!
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
Update:

I removed the solenoid. For anyone else who was wondering, I removed the transmission shifter. It's not bad, certainly no worse than what you took apart to get this far just drill out the 6 or so rivets and fanangle it out of the hole..

Once the transmission shifter is out, the solenoid can be easily seen on the t-case. Remove the 4 bolts and attempt to pop it off. I say attempt because mine was pretty stuck on there. A few taps with a hammer and it was loose.

Now..

I played around with the t-case shifter and I have good movement foreward <-> back and left <-> right. So I started to re-install the console, I have the boot on the t-case shifter.....

BUT..When the shifter is positioned in High (toward the back) it doesn't stay there, it pops foreward.

Thoughts?
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
I just took it for a ride. It poped out of high and in to neutral twice. Both times I stopped, put the trans in N and then the t-case into H.

I also stopped at a big dirt parking lot to tinker with it. The diff lock seems to be working in low and high, the light even illuminates. Low range works as well.

As I was leaving the lot and heading home something began making noise. Sounded like maybe a warning chime but it was a solid tone. When I got home I shut the vehicle off, re-started and it stopped..
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
I figured out what the warning is, it means the t-case is in neutral.


Any help for why it isn't staying in high range?
 

franko

Member
Jan 4, 2010
8
0
Newb question, what is the solenoid actually doing, and how come when you remove it. You can then shift better. I ask because Iam having the same issue. My t-case shift is stuck and the truck will not move anywhere.
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
Newb question, what is the solenoid actually doing, and how come when you remove it. You can then shift better. I ask because Iam having the same issue. My t-case shift is stuck and the truck will not move anywhere.

The way I understand it is that it is a safety feature that keeps you from accidently shifting into low range. When mine apparently failed it locked my t-case into high range. I have read of others who have had theirs locked in low.
 
Last edited:

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
Adjustment of the linkage?
I tried to adjust the portion with the splined shaft to where it had full throw throughout the hi-low range of motion.

Wear in the transfer case/linkage?
Maybe the end on the arm that sticks out of the t-case?

Busted motor mounts?
No idea, hadn't thought of that. Aside from this ordeal, it doesn't do anything (that I recognize) that would indicate bad motor mounts.
 
franko said:
Newb question, what is the solenoid actually doing, and how come when you remove it. You can then shift better. I ask because Iam having the same issue. My t-case shift is stuck and the truck will not move anywhere.

The solenoid prevents you from shifting from high to low if the transmission isn't in neutral (soccer-mom insurance for Rover). In your case, it sounds like a seized transfer case shifter.
 

franko

Member
Jan 4, 2010
8
0
ptschram said:
The solenoid prevents you from shifting from high to low if the transmission isn't in neutral (soccer-mom insurance for Rover). In your case, it sounds like a seized transfer case shifter.

Thanks man , and the best thing for a seized transfer case shifter is ?
Lots of lube lol
 

RoverRideAlong

Well-known member
Apr 23, 2005
629
0
Versailles, Kentucky
ptschram said:
Busted motor mounts?

I would take a look at both the motor mounts and transmission mounts, won't take you 30 seconds to check. My transfer case started acting up, turned out all 4 mounts were trashed. Replaced the mounts and it shifts soo smooth now thats its back in line.
 

Jay5oh

Active member
Mar 15, 2010
34
0
SW PA
I think I have mine working and staying engaged in 4hi now. I gave the shifter a good pull instead of a gentle tug and it hasn't disengaged yet. I haven't driven it much but so far so good...

Thanks to all for the help!