Yes another 03 CDL post

[degride]

So I finally got around to installing the D1 shifter into my truck which has had a locking t-case in it for over a year now. After reading basically all the threads on dweb as well as the discovery2.co.uk install guide and Rave I've come to realize I'm officially throwing in the towel.

Here are my questions/issues I have in no particular order:

1. How to tell if CDL is engaged without dash light (I raised the front end, put it in drive, shifted tcase knob to left and both front wheels did not turn upon applying light throttle (which I'm assuming means tcase is locked). However, I unlocked tcase by shifting back to the right and still, wheels did not turn).

2. Diff-lock switch is not plugged into anything (hence reason in question 1 above, no dash light I'm assuming). I cannot find any available Lucars connectors to plug onto switch anywhere underneath. I see that I can order the diff lock harness here http://www.roverparts.com/Parts/YMQ105170G but I can't see anywhere where I would plug it in. I'm wondering if LR completely omitted the harness piece on 03 models and even with buying the harness above not having anything to plug it into.

3. Did I mention, how can I tell if tcase is locked? Is there another way to tell without removing front driveshaft?

At this point, with everything buttoned up I'm fine with the D1 shifter but with hindsight I wish I had went with an 04 shifter instead. But honestly I haven't really needed it with all the places in Utah, CO, BC and Mexico this truck has been. It has taken some creative driving without it but I'm glad I finally have it especially given the mileage I've racked up.

Thanks

 

[squirt]

Lock the T-case, put the transmission in Park and shut the engine off.

Jack up one wheel - make sure the other three are on the ground.

Spin that wheel. If the wheel turns, the T-case is not really locked.

 

[ezzzzzzz]

I don't think the 03 had CDL, only the 04 but I see you've installed an earlier Tcase(?). If the difflock light switch is not installed to the proper height the shift rod will not move fully preventing CDL engagement (and the light will never come on). I've seen this issue in more than one truck over the years. Also, the CDL engagement doesn't just happen as the splines have to line up before full engagement. I'd disconnect the CDL light switch and short it out to confirm the dashlight comes on. If it does you'll need to loosen the lock nut on that switch and back it out slightly (It should be about 1/8" clearance). Also, there should be two switches on the Tcase that associate with hi/low. One is on top and just forward of the lockout solenoid. The other is on the upper front of the output housing (inline with the hi/low shift rod when it exist). I swapped out the Tcase front housing on my 02 with an earlier one with CDL only then realizing the switch wasn't there on that housing. I had to install a switch in the dash to tell the SLABS that low/hi was engaged. My traction light occasionally comes on when operating in difflock. I'm swapping out to a later SLABS hoping the later programming works better with CDL.

 

[degride]

Jacked one wheel up, all others were on the ground and the lifted wheel would not rotate. That being said, the tcase will not unlock which is leading me to my issue. Even with the linkage disconnected and manually turning the nipple on the tcase it will not unlock.

Any other tricks before I have to succumb to dropping the case out which I really do not want to do.

As far as the connector to the diff lock switch, it's not connected because there are no connectors coming off of the harness to plug onto the connector itself. Does anyone know where in the harness you would plug the diff lock connector harness "add-on" referenced in first post? Not that I need it but it would be nice to have.

Thanks again

 

[K-rover]

Sometimes you need to drive it forward or backwards for a few feet before it unlocks..

 

[degride]

Copy that. I've driven a few miles with it supposedly unlocked (shifter knob to the right towards passenger as far as it will go) to no avail.

I also confirmed that I do not have the lucars connectors zip tied anywhere on the main harness so unless I want to splice into the existing harness I'll let it go for now. This is related to the diff-lock indicator on the dash.

The bigger issue is getting the t-case unlocked. What's interesting is that since I've had this case in for over a year now with trips everywhere here in CO, UT and Baja it hasn't been an issue because it's always been unlocked. Only since I installed the shifter linkage have I encountered this issue.

I'll go and bang my head on the cross-member some more and maybe tear apart the center console again. If you have any other pointers I'm all ears.

Thanks

 

[degride]

Solved.

Moved CDL shifter into locked position, backed up on pavement with steering wheel completely locked to one side and bam! Not bam as in something broke, but bam as in I freed the t-case.

Now just gotta track down other vibration.