Drivetrain - Difficult Differential Lock Selection

No: 41/02/98/NAS
Ref:
Issue: 1
Date: 10/23/98

Difficult Differential Lock Selection

AFFECTED VEHICLE RANGE:

DISCOVERY (LJ) up to WA794728
DEFENDER (LD) All

SITUATION:
INABILITY TO SELECT OR DISENGAGE DIFFERENTIAL LOCK

Difficulty may be experienced engaging or disengaging the differential lock. The differential lock warning light may operate normally, despite the engagement difficulties.

RESOLUTION:
NEW SWITCH LOCATION SYSTEM ELIMINATES INTERFERENCE WITH LOCK MECHANISM

Use of a switch spacer and new tightening specifications ensures that the differential lock warning light switch is properly positioned and will not interfere with differential lock engagement or disengagement.

PARTS INFORMATION:

PRC2911 Switch, differential lock warning light
UYF100160 Spacer, differential lock warning light switch
LRN21456 Loctite 577 Thread sealant compound

WARRANTY CLAIMS:

41.20.34 Discovery Time 1.75 hrs.
Defender Time 1.00 hr.
Replace differential lock warning light switch with new component

FAULT CODE: U

Normal warranty policy and procedures apply

REPAIR PROCEDURE:

INSTALLATION OF SPACER WITH REPLACEMENT SWITCH

NOTE:
Any time the differential lock warning light switch is replaced, use of the newly introduced spacer will ensure proper adjustment.

1. Determine that warning light switch is the cause of differential lock engagement difficulties as follows:

^ Back out the switch slightly.

^ Move the differential lock lever to check engagement.

2. If the switch is the cause, remove the old switch.





3. Orient spacer (UYF100160) with recess toward switch head (Figure 1).





4. Install spacer onto replacement switch (PRC2911) and tighten until snug against the head with no visible gap (Figure 2).





5. Apply Loctite 577 to switch threads and install on front output housing (Figure 3).

6. Hand tighten switch until contact is made between the spacer and the housing.

CAUTION:
Apply torque to the spacer, not to the switch. Damage to the switch may result if incorrect torque procedures are followed.

7. Place wrench on spacer and torque spacer/switch assembly toll Nm (100 lbf.in.).