I'm finally getting around to doing this. I've had the linkage for a while now.
When I ordered the linkage from EE, I called Tillery up and got a replacement transmission tunnel plate, the black one, that the shifter and the CDL lever attach to. I ordered this, as I had previously installed the DI linkage, and for that I had to cut too much off to get the 04 to mount up properly.
I just made the cut, and cleaned the new plate up, making sure all the rivets were completely out of it. In the process, I managed to bugger the foam gasket that goes around the edge and mates with the bodywork. I cleaned what was left of the foam gasket off entirely, using Googone, and when I wash it with spirits, I'll sand it down a bit and prime and paint the whole thing. I bought a can each of the Rustoleum industrial flat gray primer and flat black topcoat for this purpose.
I also picked up a roll of the rubberized gasket material with cork in it, of approximately the same thickness as the crushed foam gasket, perhaps a bit thicker. I'll cut a matching gasket out of this stuff and apply it to the the new plate with high temp black silicone tomorrow. Do you guys think I should silicone the other side as well when I install it? I've been considering it.
So, the plate should be pretty much good, with a new gasket, new paint, and a new hole, which looks far better than the one I did before. Here is a tip, use a jigsaw. Last time I did this, all I had was a Dremel and a cutoff wheel, and that SUCKED. The Jigsaw made short work of the job, and I used the Dremel to clean it up.
Unfortunately, having installed the DI linkage before, I naturally managed to go ahead and lose the hardware to attach the shifter housing to the tunnel plate. No worries, though, as believe it or not, I found the proper hardware at Lowes, as well as the blue Loctite I wanted to use when installing it.
Sadly, however, I do not know if I have the hardware that attaches the cable bracket to the transfer case. To clarify, I speak of the actual CDL engage/disengage cable. On the business end, the end opposite the actual shifter, there is a bracket that the cable passes through. This bracket is meant to attach to the transfer case adjacent to the CDL nipple. There are apparently two bolts that accomplish this, and let's assume that I do not have them. Does anyone know what bolts I need to purchase for this bracket? I'm sure one of you buggers got it all apart and realized at that point you needed them. I don't want that to happen to me again.
And one more question, this is the stupid one. Before I go and get into this, I'd like to know how the shifter housing for the 04 linkage should be oriented upon install. To make the question and answer clear, I'll specify some things.
On the shifter housing, there is a mounting horn with two cable passthroughs drilled into it. This horn extends out significantly from the housing itself, and is a good indicator of direction. In which direction should this horn face upon install? Answer American drivers side, American passenger side, hood or tail lamps. This will make things clear for everyone.
I want to make damn sure when I get into this irritating job again that it goes as smoothly as possible. I don't have much dexterity, and it's tight in there, and that will be actively irritating me the whole time. And I just can't remember how the factory horn was oriented anymore. I can't even find a picture of it anywhere. I like to know things up front, to eliminate guesswork. I'd like to spare my guesswork neurons for when I really need them.
For anyone considering this job, it isn't that it's particularly skill oriented or requiring many steps, it's just tedious. The DI linkage was pretty darned irritating, but it is a job anyone with patience can do. I expect this one to be a bit easier, but I haven't done it before, and I know how cables can get. I will tell you, however, that the difference is night and day, and it is worth all the trouble in the world to have that CDL. I will also say that I was happy to spend the money on the 04 linkage after living with the DI linkage, so do what you can afford, and don't say I didn't warn you.
Cheers,
Kennith
When I ordered the linkage from EE, I called Tillery up and got a replacement transmission tunnel plate, the black one, that the shifter and the CDL lever attach to. I ordered this, as I had previously installed the DI linkage, and for that I had to cut too much off to get the 04 to mount up properly.
I just made the cut, and cleaned the new plate up, making sure all the rivets were completely out of it. In the process, I managed to bugger the foam gasket that goes around the edge and mates with the bodywork. I cleaned what was left of the foam gasket off entirely, using Googone, and when I wash it with spirits, I'll sand it down a bit and prime and paint the whole thing. I bought a can each of the Rustoleum industrial flat gray primer and flat black topcoat for this purpose.
I also picked up a roll of the rubberized gasket material with cork in it, of approximately the same thickness as the crushed foam gasket, perhaps a bit thicker. I'll cut a matching gasket out of this stuff and apply it to the the new plate with high temp black silicone tomorrow. Do you guys think I should silicone the other side as well when I install it? I've been considering it.
So, the plate should be pretty much good, with a new gasket, new paint, and a new hole, which looks far better than the one I did before. Here is a tip, use a jigsaw. Last time I did this, all I had was a Dremel and a cutoff wheel, and that SUCKED. The Jigsaw made short work of the job, and I used the Dremel to clean it up.
Unfortunately, having installed the DI linkage before, I naturally managed to go ahead and lose the hardware to attach the shifter housing to the tunnel plate. No worries, though, as believe it or not, I found the proper hardware at Lowes, as well as the blue Loctite I wanted to use when installing it.
Sadly, however, I do not know if I have the hardware that attaches the cable bracket to the transfer case. To clarify, I speak of the actual CDL engage/disengage cable. On the business end, the end opposite the actual shifter, there is a bracket that the cable passes through. This bracket is meant to attach to the transfer case adjacent to the CDL nipple. There are apparently two bolts that accomplish this, and let's assume that I do not have them. Does anyone know what bolts I need to purchase for this bracket? I'm sure one of you buggers got it all apart and realized at that point you needed them. I don't want that to happen to me again.
And one more question, this is the stupid one. Before I go and get into this, I'd like to know how the shifter housing for the 04 linkage should be oriented upon install. To make the question and answer clear, I'll specify some things.
On the shifter housing, there is a mounting horn with two cable passthroughs drilled into it. This horn extends out significantly from the housing itself, and is a good indicator of direction. In which direction should this horn face upon install? Answer American drivers side, American passenger side, hood or tail lamps. This will make things clear for everyone.
I want to make damn sure when I get into this irritating job again that it goes as smoothly as possible. I don't have much dexterity, and it's tight in there, and that will be actively irritating me the whole time. And I just can't remember how the factory horn was oriented anymore. I can't even find a picture of it anywhere. I like to know things up front, to eliminate guesswork. I'd like to spare my guesswork neurons for when I really need them.
For anyone considering this job, it isn't that it's particularly skill oriented or requiring many steps, it's just tedious. The DI linkage was pretty darned irritating, but it is a job anyone with patience can do. I expect this one to be a bit easier, but I haven't done it before, and I know how cables can get. I will tell you, however, that the difference is night and day, and it is worth all the trouble in the world to have that CDL. I will also say that I was happy to spend the money on the 04 linkage after living with the DI linkage, so do what you can afford, and don't say I didn't warn you.
Cheers,
Kennith
