I found a guy parting out a D1 transfer case locally and I was wondering if it is compatible for a 2003 Discovery?

My t-case is leaking, and if I could get this D1 t case cheap enough I was planning on resealing it and or rebuilding it and then possible picking up an 04 air shifter. So eventually after getting the D1 tcase up to par I could just swap it out with my 2003. Is that doable or impractical?

 

It is compatible, I am not 100% sure of that, more like 80%.
If you can get it cheap enough try it and see, if it wont work then sell it for a profit.

 

With the DI t/c you will not need the air shifter, it already has a mechanical linkage.

Just do not overpay for it to begin with or you will be throwing more away than you think. The more DI's that are junked means more of these are available which makes their resale value less as well as a shrinking demand as well.

 

Is the D1 CDL reliable though? I've heard the 04 shifter is better than the mechanical linkage. But that kind of came as a surprise to me as I would think the D1 linkage would be more reliable and less prone to failure, but I guess they suffer from corrosion?

What's the best way to maintain/lubricate the mechanical linkage? And since the t-case is a 95, what are the odds of the gears being worn out? I know the LT230 is supposed to be tough as nails. But would I be doing my self a disservice by replacing my t-case with one that is 8 years older? Are new gears affordable options?

 

Take a look at the following parts page from Rover's North, it shows the DI linkage.

Land Rover Discovery I Transmission Levers, Linkage Parts Available from RoversNorth.com

Here's the transfer case:

Land Rover Discovery I Transfer Case Parts Available from RoversNorth.com


At some point (I do not know which) LR first merly did away with the linkage but left the locking portion there but no way to lock it, then they did another change then they made it the linkage you speak of. Do some research to learn the exact differences. It is well documented in several other places.

 

D2 2003 have same transfer case as 1995 D1 , except it doesn't have central dif lock , LR enginers figured out traction control on D2 is adequate , but people liked that manual lock so LR put it back on 2004 model.Now if you install that transfer case from 1995 D1 , you will have both central differential manual lock and traction control which is great.

 

Completely wrong. First 95 and 96 D1 cases had a number of oiling issues, there were probably 6 or 8 changes made in the r/case over the years and as such that is the last case you want in your 03.
Why not buy a linkage and the front CDL nose assembly from any of the D2 cases and rebuild your 03 case, a lot of people are starting to do it, the nose assembly will run you $75 and depending on the linkage, $125 to $375.

 

If you want to install a DI LT230 in a DII you will need to do the following.

1) Keep the front output flange from the DII. The DI output flange is smaller and will not work with the DII front driveshaft.

2) You will need to transfer over all of the wiring assembly to the DI.

3) If you were going the other direction, I would tell you that you need to install the rear output assembly from the DI on to the DII so you can still use the VSS. BUT since the speed is not taken from the VSS on the DII I guess you could leave well enough alone and use the DI rear output assembly.

4) Enlarge the hole in the transmission cover to enable the greater shifting range of the DI LT230 with CDL.

I'm sure I've missed something and smarter minds then I will add to the list but for the time being, what you want to do is relatively easy.

One of the nice things about using the DI LT230 with the DI linkage is that the linkage will line up nicely with the arm coming from the hi/lo cover. A small but simple thing. If you were installing the DI linkage on a DII LT230 I would recommend sourcing a DI hi/lo cover but you'll be set.

 

Mike and I posted at the same time. I actually have all the items he mentioned in his post should you want to go that route.

 

Good to see you are up and at it already this morning, Paul.