Use to own a D2 and there are a lot of places to get parts and equipment for these monsters. You biggest concern is with the fact the D2 is a ’03. If it was made the front half the year there is no CDL ability in the transfer case. Without a CDL system, you are stuck with the traction control system. Traction control does not work to well; the speed sensors have a lot of issues. If the brakes sequel for to long the Hall Effect sensors magnets will shatter, give the dreaded three amigos. To get CDL, all you need to do is swap out the T-case front output with a ’99-’01 unit and then add a ’04 lever. This mod takes about 2 hours. Then there is the rear drive shaft. It uses the roto flex system, or better known as the rubber donut. Go to Great Basin Rovers and talk to Bill to get the conversion to a real u-joint and put on a decent rear drive line. Now for the front drive shaft. This is not grease able, and it sits way to close to the catalytic converters. Making the grease boil off and having the camber explode, taking out your oil pan, catalytic converters and transmission. No need to replace the drive shaft, it is well built. All you need to do is make it better by adding real u-joints and having a machine shop make a grease able pivot bearing for you. The front drive shaft uses the same u-joints from a Volvo 500 series.
I could go on for ever on modifications on these things. I did love mine until the engine fire when the oil cooler line busted. Still have it in my yard and I cry every time I see it, and when I think I put in over $22,000 in modifications into it. Oh well, such is life. Now it is time to build a new rig and building is half the fun.
By the way, Discoweb is a good source of information. Just don't ask any questions and do the oppisite to what some of them tell others to do.
Later
