Disco 2 Transfer Case solenoid

[HiDesign10]

Hi,
I am a fairly new owner of a 2003 Discovery and have learned a lot about the many idiosyncrasies of Land Rovers since finding this forum. Thanks to all for the education! I fixed the leaking sunroof drains and the leaking rocker cover gasket. I swapped out the Transfer Case when it started to make a bad Knocking noise, but only on a trailing throttle at more than 25 mph. Opening up this original Transfer Case after it was out of the car, I find that everything seems to be in good shape except that something made from copper or bronze has been floating around inside there, getting minced up into metal dust and tiny flakes floating in the oil. Most of the lager debris flakes seem to have congregated within the front output shaft housing and the adjacent taper roller bearing cage. I'm curious as to what the source might have been since there does not appear to be any copper or bronze components within the Transfer Case in the first place, and everything spins smoothly without excess clearances once the debris was flushed out. Any ideas anyone?

Now to my real question. The "new" used Transfer Case that I was able to get is from a year or two older than my 2003 model. It has the CDL with no actuator lever or bracket, and the large Hi/Lo interlock solenoid. I was able to swap over various sensors/switches to keep the mating harness connectors etc., the front prop shaft companion flange and the Hi/Lo shift lever to the 2003 type. I am left with an interlock solenoid in the Transfer Case which does not work and the original 2003 interlock in the shifter cable mechanism that does! The Rave manual does not tell how to remove the solenoid from pre-2003 Transfer Cases. Can anyone suggest how to do that?

Thanks,

Tom

 

[Disco Mike]

Take off the 4 bolts that hold the solenoid housing, remove the solenoid and reseal the the cap back onto the top of the t/case.

 

[HiDesign10]

Thank you for the reply Mike.
I had already removed the housing before the T'Case went into the car, but the solenoid body seemed pretty well fixed into the main case. I did not want to damage anything by not knowing how the solenoid was attached to the main case or the shift rod, so I resealed and put the housing back on. Maybe it is just stuck in there with the RTV sealant or a tight fit into the main case. Should the solenoid just pull out of the main case and disengage from the shift rod if I tap on it with a mallet?

Tom

 

[Disco Mike]

The solenoid should have pulled right out, it is not attached to anything.