| Author |
Message |
    
Rob Vreeland (Cruzths)
| | Posted on Monday, September 09, 2002 - 06:18 pm: | 
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This weekend I completed (well, a mechanic friend and I) a complete CDL retrofit in my 2002 Disco. I located a transfer case with CDL bolt on a wrecked 2001 Disco with only 7000 miles on it. To engage the CDL I purchased the solenoid kit from GBR.
The install tool much longer than expected as I don't think LR wants anyone to replace their transfer case. Forget doing it on the trail. We had a full shop with lifts and air tools and every other tool know to man (including the RAVE CD) and it still took a total of about 14 hours (3 of those was removing and replacing the center console and the rivited plate that leads to the transfer case).
I'm very happy with the new CDL but don't wish the install hell on my worst enemy. Please do not try it in your driveway.
Rob |
muskyman
| | Posted on Monday, September 09, 2002 - 06:55 pm: |
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was the mechanic familiar with Rovers?
old saying
hourly rate
$30 an hour
$50 if you watch
$100 if you help
14 hours sounds like alot of time?
it will be worth it...it can take that long to get a one wheel drive truck out of the places it gets stuck over the life of your truck. |
Rob Vreeland (Cruzths)
| | Posted on Monday, September 09, 2002 - 07:36 pm: |
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The mechanic was framiliar with Rovers but never had to replace a transfer case. Basically it took him about 4 hours to remove the TC, 1 hour to prepare the new TC (wires, CDL solenoid, cleaning), 6 hours to install the new TC (it took just over an hour to get it back in it's place and lined up with all the mounts) and 3 hours to remove center console, hook up the CDL and put it all back together.
Cost:
Used TC from junk yard - $900
Solenoid Kit - $350
Labor and use of shop on the weekend - $500
CDL in a 2002 Disco - Priceless
We also did a Safari Gard front bumper w/winch install, new OME steering damper, diff guards and nearly completed my new steel rear bumper (pictures will follow). |
Craig Kobayashi (Koby)
| | Posted on Monday, September 09, 2002 - 07:54 pm: |
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Rob-
Who did the work on your Disco?
You live in the San Jose / South Bay area, correct? |
Rob Vreeland (Cruzths)
| | Posted on Monday, September 09, 2002 - 08:00 pm: |
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www.4x4labs.com - They are in Grass Valley (about 3 hours from San Jose). Their speciality is custom bumpers, roll cages and roof racks (however they have a full-time mechanic that does all the engine and gear work). Wait until you see my new rear bumper that they made. It should be ready and installed in about 2 weeks.
Yes, I'm in San Jose. |
Kim S (Roverine)
| | Posted on Monday, September 09, 2002 - 09:25 pm: |
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Wow Rob, I'm impressed ... you really wanted to fix that thing! When you mentioned 2002 D2, I thought, "uh-oh". Bless your heart  ... LOL, I have an '01 (I've had it locked before, long story), and I even bought the D1 linkage a few months back, but still haven't done anything about it. ... I think in my case it would be called the old "paralysis through analysis" syndrome. I keep thinking maybe I want to go solenoid vs. mechanical linkage install, then maybe not. Then it doesn't matter because something comes up and I don't have the time or resources for either way, LOL. Well, kudos to you for your new mods!
Kim
P.S. Craig, how is your solenoid actuator working out? |
KJ
| | Posted on Monday, September 09, 2002 - 11:26 pm: |
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God Kim, I'm so impressed when I read your jock talk! LOL, I mean that! Some of it I even understand.
Karen |
Ron
| | Posted on Monday, September 09, 2002 - 11:30 pm: |
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Why did you not just swap front output housings?
Did you consider that option?
Ron |
Rob Vreeland (Cruzths)
| | Posted on Tuesday, September 10, 2002 - 11:47 am: |
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Ron - We did consider that option but found it was diificult to find just that part and it would have taken about as long to do the install. And I was very happy with finding the TCase for $900.
After the install the mechanic (Tyler) said now that he has done it would probably take him less than 6 hours to do it again.
To any 01-02 Disco owners without the CDL bolt, just wanted to let you know that all the electronics for CDL (the sensor and dashboard light) are all in place in your truck and will work fine after the install. The wires for the sensor were taped up on the wire harness on my truck and just needed to be plugged in to the new TCase.
Rob |
Kim S (Roverine)
| | Posted on Tuesday, September 10, 2002 - 12:41 pm: |
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"The wires for the sensor were taped up on the wire harness on my truck and just needed to be plugged in to the new TCase."
hmmmmm, even though I do have the CDL bolt, maybe this explains a few things about my sensors and lights not working ... so ... if the sensor didn't work, maybe that's why the ETC and ABS both still seemed to be engaged when my CDL bolt was locked? (I had a new T case put in at 700 miles, and it was installed with the CDL bolt in the locked position). I would have thought they would have checked for the sensor wires, but maybe the service mngr thought of that after they reinstalled the T case? Rob, can you find the wires easily?
KJ - LOL, don't be impressed, (but glad you understand some of it ;-) "Jock talk"? ... I dunno about that ... most of this I learned the hard way, and I still don't have a clue, LOL.
Kim |
Rob Vreeland (Cruzths)
| | Posted on Tuesday, September 10, 2002 - 01:53 pm: |
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Kim - I'll have to crawl under my truck and see how easy it is to get to the sensor and wires but here is what I remember.
If you are under your car looking up at the TCase (your head towards the front of your truck), the sensor is 2 prongs to the right (your right) and down (closer to the ground) from the CDL bolt. There should be 2 wires (each with their own plug) attached to the sensor.
As for the wires.. Above the TCase is a wire harness that contains several plugs. It is the largest wire harness above the TCase. The 2 wires for the CDL were taped up against the harness with a small piece of black tape. They are very easy to get to if you remove the center console (however the center console was a project in itself to remove and replace).
Hope that helps. If not, I'll crawl under my car after I get home from work and take a picture (if I can).
Rob |
dan
| | Posted on Tuesday, September 10, 2002 - 02:01 pm: |
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my discoII was built on 4/2001.. does anyone know if it's CDL installable? |
Kim S (Roverine)
| | Posted on Tuesday, September 10, 2002 - 04:36 pm: |
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Thanks, Rob.
Dan, I think the best way to find out is to wait until your truck is cooled down well, and crawl under and see for yourself ... You can reach up and actually feel it ... I'm sorry I can't describe it to you very well, but I am a mechanical retard, and I don't know how to describe it. I would take a pic, but I cannot do that right now, and I don't have photoshop to paint a line showing you anyway. I'm pretty sure there is a good description in the archives here. Otherwise, maybe someone else can help out here?
FWIW, I picked up my '01 D2 pretty much straight off the boat in mid March ('01), and the manufacter stamp/date says Oct. '00.
Kim |
chris
| | Posted on Tuesday, September 10, 2002 - 09:32 pm: |
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Wow Rob, as a fellow 02 Disco owner you've given me hope. Does anyone know of a mechanic in Houston that has experience doing this? |
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