UPDATED: DI CDL Installation Instructions for DII

LSUDenver

LSUDenver

Well-known member
Apr 30, 2007
150
0
Denver, Colorado
Disco Webers, I recently used Morris Jessup's instructions on installing a DI CDL lever in a DII. They were a decent guide, but I took pictures through 90% of my process and was able to drastically update his original document. Its now 21 pages, but it will get the job done.

I am posting all of my pictures and my version of the updated guide here for free distribution. If you think that there is something that I have missed, then shoot me an email and let me know.

Photos: http://dpwarren.com/disco/cdl/

Guide Manual: http://dpwarren.com/disco/cdl/doc/DI_CDL_Install_2008-8-24.pdfhttp://dpwarren.com/disco/cdl/doc

Enjoy,

David P. Warren
david@dpwarren.com
 
Last edited:
M

mowthat

Guest
I remeber someone saying you had to remove the driver side cup holder after doing this so the shifter has the clearance needed to engage the cdl. Is this the case?
 
scottjal

scottjal

Well-known member
Mar 16, 2006
1,484
0
Nashua, NH
scottjal.ath.cx
mowthat said:
I remeber someone saying you had to remove the driver side cup holder after doing this so the shifter has the clearance needed to engage the cdl. Is this the case?
Click to expand...

Don't have to remove it but you might have to sneak it back a bit to clear. I followed the directions that came with the cup holders and measured their layout when I installed them, and when I later added the DI CDL it all just fit and worked fine. It does come pretty close to the holder though.
 
U

UK 4X4

Well-known member
Jul 6, 2006
704
0
Planet earth currently Oman
One important item missed.

whilst you have all the mid section of the truck removed spend the extra hour and remove the high low disable solenoid.

This will save you from pain at a later date.......its a solenoid that stops you shifting the high low lever at speed.

It is only fitted to NAS trucks.

and when fails.........means you can't shift from high to low and visaversa.

Top of the transfer case RHS round 2" bump with 4 bolts holding it down and a small wire exiting rear

In my 2000 I had to bend a connector mounting plate up out of the way to get to the front bolts.

beat with hammer to loosen then extract verticly upwards.

On the bench pry out the solenoid and throw away

refit housing with sealant and a little piece of rubber.
 
LSUDenver

LSUDenver

Well-known member
Apr 30, 2007
150
0
Denver, Colorado
UK 4X4 said:
One important item missed.

whilst you have all the mid section of the truck removed spend the extra hour and remove the high low disable solenoid.
Click to expand...

Good Idea and I wish that I would have known when I was in there. Do you ahve any photos of this surgery?
 
U

UK 4X4

Well-known member
Jul 6, 2006
704
0
Planet earth currently Oman
No photo's...yesterday I drove 70 miles to the trail head could'nt shift.......drove 70 miles back and spent 3 hrs ripping the bastard thing out.

Something I missed when installing the lever.....then again when I broke the linkage (due to the solenoid I did'nt know existed)

oh and when refitting, use sheet metal screws instead of rivet's so you can get access if required on the trail with drills etc
 
SDD2

SDD2

Well-known member
May 20, 2006
800
0
A major pain to remove, but worth the effort ...

UK 4X4 said:
One important item missed.

whilst you have all the mid section of the truck removed spend the extra hour and remove the high low disable solenoid.

This will save you from pain at a later date.......its a solenoid that stops you shifting the high low lever at speed.

It is only fitted to NAS trucks.

and when fails.........means you can't shift from high to low and visaversa.

Top of the transfer case RHS round 2" bump with 4 bolts holding it down and a small wire exiting rear

In my 2000 I had to bend a connector mounting plate up out of the way to get to the front bolts.

beat with hammer to loosen then extract verticly upwards.

On the bench pry out the solenoid and throw away

refit housing with sealant and a little piece of rubber.
Click to expand...
 
S

stanigu

New member
Jan 22, 2007
2
0
Great write up!

I was going to attempt this last weekend, but got stuck on one of the very first steps: removing the shifter knob from the PRNDL thing. I know it's just pressed on, but man, it's on super tight! Did you just yank on it, or use some tool?
 
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