AzRover
Observer
I picked up my cdl transfer case from a local junk yard for $150, if I remember correctly. It was from a 01 Disco. I had to replace the cdl lock switch.
It also came with a wiring harness, parking brake, and high/low shift cable. They were useful. I took from the harness the wiring to connect the CDL lock switch.
Also think about rebuilding your front drive shaft while your at it. Finding the 04 shifter for a low price was the bigger challenge. I found both the transfer case and shifter using http://car-part.com/ . I Think the whole project cost about $400.There are allways little extra expences. You will need to make a fixture for supporting the transfer case. The Disco 1 workshop manual has the plans for it. I just made one out of plywood, and added some extra supports. I mounted that to a harbor frieght transmission jack. Its also helpfull to get some studs to use as guides for aligning the bolt holes on the transfer case, to the transmission. You will also need a new transmission output shaft seal, and may be the shaft, if it's worn and leaking. Also, You need to remove the exhaust, so get some new gaskets, and hardware.
I replaced the whole transfer case because my old case had run low on oil, and I found a piece of metal in the oil that I drained from it.
I wanted to flush the transfer case woth oil. So I filled it, ran it, then drained, and filled it. Don't do what I did, that's getting the wheels spinning while up on 4 jack stands. One wheel will spin very fast, even at idle. The breaks won't stop it. I just had to kill the engine. The ABS system doesn't like that.
Here are some links that I found helpfull.
http://www.discoweb.org/forums/showthread.php?t=48003
http://www.landroverclubvi.com/2003cdlinstall.html
http://www.discovery2.co.uk/diff_lock.html
Also, with the transfer case out, you don't have to remove the shifter mounting plate to install the shifter. As shown in the 3rd link.
Good luck,
Steve
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