Great Basin Rovers / Range-Rov.com.au

CDL Solenoid Installation
by Craig Kobayashi, with thanks to Dave Marchand

Tools required:

Drill
Pop-rivet gun
Metric socket set with extensions
Phillips head screwdrivers
Small adjustable wrench
Soldering iron
   

Parts required:

Electric Solenoid CDL kit from Great Basin Rovers (http://www.greatbasinrovers.com)
3/8" rivets
Heat shrink solder wrap
Solder
Additional wire (black and red)
Zip ties
Rear wiper binnacle switch (optional)
The main problem with installation of this kit was the poor documentation.  This is from the instructions provided by Range-Rov Automotive.  The diagram is vague, especially when compared to the actual wire harness.

This is the diagram labeled with the corresponding wires


  • For center console disassembly and reassembly, please refer to the excellent Morris Jessup instructions at Expedition Exchange.

  • Installation of each component is fairly straightforward. I have included pictures of where I installed each component. I did not include pictures of the wiring as this can vary with each installation.

  • I opted not to use the switch provided by GBR as I wanted to maintain a stealthy and as stock as possible appearance, so I purchased a rear windshield wiper binnacle switch (LR part number: YUE100600) from Dan at  www.britishrecycling.com.

  • Extension of the solenoid activation switch (long black wire) will need to be added because the GBR solenoid kit is actually imported from Australia and designed for right-hand drive model Disco 2s. I drive a left-hand drive Disco 2, so this addition was necessary because I wanted my switch on the driver's binnacle.

  • The hardest part about the installation is the adjustment because the solenoid will burn out if not allowed to retract completely.  This adjustment is not difficult if done properly.  To adjust the CDL lever travel, I activated the solenoid when it was not connected to the CDL nut.  I then connected the solenoid to the CDL lever, thus ensuring the solenoid has reached its full travel.   Very little adjustment was needed.

solenoid01_small.jpg
Exposed transmission and transfer case

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CDL mechanism with nut-linkage interface

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Another view of the exposed transmission and transfer case

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Loosely fitted solenoid not yet connected to the CDL lever arm

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Solenoid with power and ground wires zip-tied to body per instructions. I also zip-tied the rubber gasket to the solenoid body for insurance

solenoid06_small.jpg
Here I am holding the +12V lead I soldered to the cigarette lighter power lead

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Switch connector with the solenoid switch (long black wire) and short red wire with inline blade fuse

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Binnacle with switches removed

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Arrangement of the power components under the hood

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Solenoid switch using a factory binnacle switch
(I am now taking suggestions on label options)

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CDL not engaged (Solenoid off)

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CDL engaged (Solenoid on)