03 Disco CDL project cost savings

shultzie

Observer
Steve.....keep us updated on the install this weekend. Is there and mods that need to be done or is it a straight bolt in. Is the wiring the same also? I won't be putting mine in for another month. Thanks again

Dave
 

AzRover

Observer
I will have to see if I have the CDL switch connection in my harness when I get under there. If not I will have to add it. The transfer case will just bolt in.
For the shifter, I may have to enlarge the opening where the stick comes through. I removed the shift interlock from the transfer case, and am thinking about removing the interlock from the shifter. I would like to be able to shift from low to high at higher speed, with the rpm's matched. I'm just not sure how well that would work. If I do keep an interlock, it will be in the shifter. That way if it fails, I can crawl under the truck, disconnect the cable, and shift it on the transfer case. I have extra parts, and my TC adaptor made up to hold it on the transmission jack. I will start Sunday.
Steve
 

AzRover

Observer
I removed the transfer case and shifter. Here are some observations.
Pulling the AT shifter knob off is a challenge.
When the TC is removed, the shifter can be removed from underneath , so the rivets don't need to be drilled out.
Looks like the opening for the shift lever works with the 04 shifter, no need to enlarge.
Tilt the transmission down while removing the TC to clear the body.
I do have the wiring for the CDL switch.
I have installed the interlock in the shifter.
I had only 2 problems. 2 of the shifter screws would not come out, had to drill them out.
I need to figure out a way to get the TC out from under the truck, the TC and transmission jack are too tall to get out. May have to lift a corner with my high lift jack, after securing the transmission with a cross member.
Steve
 

AzRover

Observer
Got the transfer case, shifter and drive shafts in today. The wires that I thought were the for the diff lock switch, were for the transfer case over temp switch. I hooked that up, the new transfer case has one. I ran some new wires, will connect them in the morning. Still need to install the exhaust.
Steve
 

AzRover

Observer
All finished, took 3 days. It works. The hi-lo cable works for the CDL. My new cdl switch is defective, internal short to ground.Will order a replacment. Just looking for oil leaks.

The old.jpg
The old.
The new.jpg
The new.
The jack.jpg
The transmission jack with wood TC adaptor.
The hole.jpg
The shifter hole, no need to cut. No need to drill out rivets when installing shifter from under the truck.
The end.jpg
The final product...
Steve
 
Last edited:

AzRover

Observer
Saved by the Prince of Darkness!!!

Installed a new Lucas diff lock switch. Everything is now working. Activate diff lock, 3 chimes and the diff lock light is on!!! :safari-rig:
 

shultzie

Observer
Nice work! Was going to install mine this month but looks like a head gasket job is up first. Thanks for the post!
 

AzRover

Observer
Went to the Bulldog Canyon OHV area today, to test the new transfer case. It worked well. CDL locked, first low, there was only one spot that I has some wheel spin, and the traction control took over. It was a moderate hill climb with loose dirt and slick rock steps. I made it up. The trail was not a real hard one, just some rough spots, but it's close to my house. I'm happy with the performance.
Steve
 

benlittle

Adventurer
All finished, took 3 days. It works. The hi-lo cable works for the CDL. My new cdl switch is defective, internal short to ground.Will order a replacment. Just looking for oil leaks.

View attachment 88963
The old.
View attachment 88964
The new.
View attachment 88965
The transmission jack with wood TC adaptor.
View attachment 88966
The shifter hole, no need to cut. No need to drill out rivets when installing shifter from under the truck.
View attachment 88967
The final product...
Steve

Nice. You even got the sticker...

I did the DI shifter in my old DII a few years back. Well worth it and it was pretty easy.
 

aarcaris94

Active member
Hello everyone,
I know this is the older thread but I have a 03 disco and want to do a CDL but am pretty lost at what I need to do. I want to do the most cost effective option so if someone could please point me in the right direction I would really appreciate it.
 

ZG

Busy Fly Fishing
Find a 99-01.5 T-case, swap the case or just front output. Cheapest would be to just go under the truck every time you need it to lock it, but it's best to find a way you get the control inside the cabin. You can grab a D1 linkage for anywhere between 100-$200.
 

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