2003 D2 - CDL Transfer Case swap out

[FLYCASTROVER]

Anyone who might be able to point me in the right direction? It would be appreciated.

I have a 2003 D2 and my understanding is that the 2003 doesn't even have the nipple/hole in the transfer case for me to connect the CDL linkage. So instead, I was told that I could buy an older CDL Transfer Case and install that with the linkage.

Before I start searching around for an older Disco, if anyone knows anything about this/has experience, and can tell me what year(s) Disco would have the appropriate case, I'd appreciate the opportunity to learn.

Thanks in advance.

Joe

 

[DiscoPhoto]

99-01.5 have the correct case, 04 has the correct case. Old D1s have the right nipple, you can use their linkage or the ashcroft, or the GBR.

I put a 99 t-case and the ashcroft linkage in mine, as mine is an 02 and had the flat top.

 

[FLYCASTROVER]

99-01.5 have the correct case, 04 has the correct case. Old D1s have the right nipple, you can use their linkage or the ashcroft, or the GBR.

I put a 99 t-case and the ashcroft linkage in mine, as mine is an 02 and had the flat top.

Thanks for the info. Sounds like just what I needed.

 

[DiscoPhoto]

You can also just swap the front output housing from a 99 if that's easier for you. If your rear tranny seal is leaking you mine as well swap the whole thing though.

 

[Keanan]

All that is really needed is to replace the front output housing/front cone. You don't have to replace the whole transfer case. If you feel like laying under the truck every time you want to engage your CDL you don't even have to mess with the linkage. Really though you are much better off fitting the D1 CDL linkage. It requires a mild amount of metal bending and cutting skills.
Replacing the front output housing with a CDL equipped output housing is not very complicated at all. It is about as difficult as rotating your tires or replacing a water pump. Connecting the linkage is the more complicated part. It is only difficult because you are trying to get things to line up properly and shift smoothly.
Here is a very detailed how to:
Pull front drive shaft
Disconnect shift linkage
Pull front output housing
Install new front output housing
Connect Hi/Low and CDL linkage
Reinstall front driveshaft (if output housing if from a DI you will need to swap the output flanges so you driveshaft will bolt up)

The average idiot could probably do this project in a day or a weekend.

 

[DiscoRover007]

All that is really needed is to replace the front output housing/front cone. You don't have to replace the whole transfer case. If you feel like laying under the truck every time you want to engage your CDL you don't even have to mess with the linkage. Really though you are much better off fitting the D1 CDL linkage. It requires a mild amount of metal bending and cutting skills.
Replacing the front output housing with a CDL equipped output housing is not very complicated at all. It is about as difficult as rotating your tires or replacing a water pump. Connecting the linkage is the more complicated part. It is only difficult because you are trying to get things to line up properly and shift smoothly.
Here is a very detailed how to:
Pull front drive shaft
Disconnect shift linkage
Pull front output housing
Install new front output housing
Connect Hi/Low and CDL linkage
Reinstall front driveshaft (if output housing if from a DI you will need to swap the output flanges so you driveshaft will bolt up)

The average idiot could probably do this project in a day or a weekend.

Isn't there a plug on the lockable transfer cases to engage the CDL light in the dash?

If going by your method, when I lock the t-case will I get the signal on the dash? Ive got an 03 and have wanted a CDL for a while.

 

[Keanan]

You could rig up the wiring to turn on the dash light. I didn't bother with it for two reasons.
1. It might not actually light up, I don't know if the 03 traction control and instrument cluster are programmed for the use of a CDL.
2. If it does light up and is programmed for it then I would have to worry about leaving my key on or off or whatever to so that when I engage my CDL it doesn't disable the traction control.

If I engage my CDL there aren't any dash lights that come on and the traction control still works as it should. It might not be the optimal setup for everyone but for me it seems to work well.

 

[jafir]

The 02 and 03 do have a light on the cluster for the CDL. Some of them might not have a harness to plug into the lock switch, or it might be hard to find tucked up behind something. I've seen a step-by-step where someone spliced into the wires to make it work.