04 CDL Linkage Install Question

dbeard

dbeard

Well-known member
Oct 14, 2011
65
0
Lebanon, PA
Hi Gang,

I am planning on installing an 04 CDL lever this weekend. After watching Justin's video, and reading a couple of articles on the install process, I have a question. I understand that I need to drill out some pop rivets to release the transfer lever mounting plate, as described in the step below.

STEP 10

Once the heater ducts are removed, you can then start to drill out the 13 pop rivets that hold the transfer lever mounting plate in position, once they are all drilled you can manoeuvre the plate out of position. It wont come right out as its still got the cable connected underneath

When I am refitting everything, what happens to this plate, now that the rivets are drilled out? Do I need to use pop rivets to refit this plate? I know this sounds noob, but I've never had to rivet anything, and I'm a little unsure what size I need, etc. Any help would be much appreciated.

Thanks

Dave
 
hilltoppersx

hilltoppersx

Well-known member
Jun 29, 2010
1,010
0
NY
www.nelrc.com
dont use rivets dave. i used sheet metal screws. comes in handy when you are on the trail and need to get in there you can unscrew them and screw them back in if necessary... instead of drilling out rivets on the trail
 
K-rover

K-rover

Well-known member
Jan 15, 2010
2,183
72
Raleigh, NC
hilltoppersx said:
dont use rivets dave. i used sheet metal screws. comes in handy when you are on the trail and need to get in there you can unscrew them and screw them back in if necessary... instead of drilling out rivets on the trail
Click to expand...


I had to take mine apart at the group camp during a Rover event after one of the clips on my D1 linkage fell off and I couldnt engage the diff lock.
Luckily I had also used some self tapping sheet metal screws so it wasnt too bad.
 
Some Dude

Some Dude

Well-known member
Feb 12, 2009
1,590
0
Boise, ID
Where'd you get the shifter? I need to throw one in mine, but last time I looked I about fell out of my chair when I saw the price.
 
K-rover

K-rover

Well-known member
Jan 15, 2010
2,183
72
Raleigh, NC
Some Dude said:
Where'd you get the shifter? I need to throw one in mine, but last time I looked I about fell out of my chair when I saw the price.
Click to expand...

Just get a D1 linkage.. People say they dont engage smoothly, but I disagree. Mine is as smooth as it can be.
 
dbeard

dbeard

Well-known member
Oct 14, 2011
65
0
Lebanon, PA
So I attempted to install the 04 shifter today. Unfortunately I'm not able to unlock CDL with the shifter. The lever does not move far enough to turn the cdl bolt far enough. If I pull the connector on the cable, then I'm able to move the bolt that little extra bit that is needed to unlock, but the lever doesn't move any further. Any thoughts on how I may be able to adjust/modify this shifter to work properly?
 
dbeard

dbeard

Well-known member
Oct 14, 2011
65
0
Lebanon, PA
If you're referring to the metal plate that the linkage bolts to, then yes, I did cut it. Plenty of room for the lever to move. But it doesn't seem to need a ton of side to side movement to do its job.
 
dbeard

dbeard

Well-known member
Oct 14, 2011
65
0
Lebanon, PA
K-rover said:
THis one may apply better.. http://www.discovery2.co.uk/diff_lock.html
Click to expand...

Here is the only part I'm a little unclear about.

Tighten the lock nuts on the diff lock cable (22MM) so it stays at the correct angle. Its only a small amount of movement to engage the diff lock. The spigot turns roughly 40 degrees to the right to engage. Now connect the cable to the new lever assembly.

I'm a little unclear about the lock nuts on the diff cable. Is there a way to adjust the amount of cable used on the cdl spigot?

I feel strongly that it has something to do with the lever. I'm only able to move the lever so far, but I'm able to pull on the connector to the cable enough that I'm able to unlock the cdl. This does require a bit of force.
 
dbeard

dbeard

Well-known member
Oct 14, 2011
65
0
Lebanon, PA
I just got a little info on another forum that says the cable is adjustable. The cable is threaded with a nut on each side of the bracket. Does this sound like it might be the ticket?
 
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