'96 D1 to '04 D2 upgrade?

[luckyjoe]

Yeah, I know I'm opening the potential problem door, but I'm thinking of replacing our 1996 SD with an 2004 D2 for daily-driver and long haul trips. Our '96 is great, and I really think it was one of the few "good" ones. However, something with fewer miles and wear-n-tear would suit us better. Is it false economy to put this faith in an '04 D2? Everything else about an '04 seems perfect for our trips, and we can take it LR events when we don't drive the 109.

So, what are the serious "2004" issues I need to avoid and/or be-aware-of when selecting a suitable D2? Are there mileage-related bombs that need to be address before driving it daily? Are there TSB's I can take to to the dealer for a free fix? What about potential transfer of parts from the D1 to the D2 (like a GBR DC fron driveshaft)?

The '96 might not go away - I haven't decided if we'll keep it, use it strictly off-road, or give to someone in our local club. More than likely it will remain in daily status, until we're 100% with the '04. If there are a few 'gotchas' I can tackle post-purchase AND drive the purchase price down, I'm OK with that. I just want to go in with my eyes open...

Thanks,

 

[stu454]

Front driveshaft will need new greaseable U joints to keep it from killing your transmission when it lets go.

Make sure the transfer case shifter goes into Low and locks since lots of soccer moms never touched it and it may be hard to move.

I would immediately change all the fluids so you have a solid baseline with the truck.

 

[dmarchand]

If you look carefully, you could find one still under CPO warranty. I'm putting mine up for sale shortly (blatant plug) to buy a RR classic, '04 SE7 gray, under CPO warranty until January 2011. Just had the HG done at 65K miles with port/polish at the dealer. Daily driver to the train station, mostly stock with small upgrades in shocks, brakes, rear backup sensor, trailer harness, block warmer, etc. My d-90 is my wheeling machine so this truly has seen no dirt.

Fluids, and 60k service done.

Otherwise, I don't think you are crazy. :victory:

 

[Ballah06]

If you look carefully, you could find one still under CPO warranty. I'm putting mine up for sale shortly (blatant plug) to buy a RR classic, '04 SE7 gray, under CPO warranty until January 2011. Just had the HG done at 65K miles with port/polish at the dealer. Daily driver to the train station, mostly stock with small upgrades in shocks, brakes, rear backup sensor, trailer harness, block warmer, etc. My d-90 is my wheeling machine so this truly has seen no dirt.

Fluids, and 60k service done.

Otherwise, I don't think you are crazy. :victory:

Another thing on the warranty, if you were to go out and get one. This is what I ve been told by the LR dealer when i got mine a few weeks ago. You cannot get EasyCare (AAPCO before) if your vehicle is over 80k. Luckily mine is at 71k, so after a brief tech inspection I got one for 3yr/36k. Just another thing to consider mileage wise.

 

[Blue]

I went from a 96 to an 04. Much more enjoyable to drive.

Issues to note:
--will need new front driveshaft with greaseable joints (as noted by Stu)
--head gaskets seem to be a frequent issue (mine were done just before I bought the truck at 49,900 miles and still fine at 68,000 miles)
--throttle body heater leaks (had gasket replaced on mine after purchase)
--valve cover leaks (replaced on mine after purchase)
--3 amigos are omnipresent
--annoying ticking at engine idle seems to be very common and there is no known cure

Those have been my issues but all in all it's a great truck. The 4.6 engine alone is worth the price of admission. The extra 6" or so in the cargo bay is also a huge bonus for me (more cargo room plus I can actually sleep in the back comfortably).

 

[brianhoberg]

I went from a 96 to an 04. Much more enjoyable to drive.

Issues to note:
--will need new front driveshaft with greaseable joints (as noted by Stu)
--head gaskets seem to be a frequent issue (mine were done just before I bought the truck at 49,900 miles and still fine at 68,000 miles)
--throttle body heater leaks (had gasket replaced on mine after purchase)
--valve cover leaks (replaced on mine after purchase)
--3 amigos are omnipresent
--annoying ticking at engine idle seems to be very common and there is no known cure

Those have been my issues but all in all it's a great truck. The 4.6 engine alone is worth the price of admission. The extra 6" or so in the cargo bay is also a huge bonus for me (more cargo room plus I can actually sleep in the back comfortably).

Good points, also add:
Get rid of the annoying pan under the engine, makes it a pain to access the engine from below.
Take care of your air box lid as to not break any of the clips, it's expensive when they go.
You'll learn to absolutely hate the air raid sound of the SAI system on the '04 and you'll find it's annoying to work around when in the engine bay.
Watch your head gasket area very carefully and keep a close eye on the water pump.

 

[luckyjoe]

Good info guys - much appreciated. I'll let you know how it progresses.

How much coin do they get for an extended warranty these days? I've never purchased one, but have a good LR friend who's made more than his money back on multiple extended warranties. Food for thought I guess...

Regards,