04 CDL Shifter in 00 Dii
 

So I attempted to install the 04 shifter today. Unfortunately I'm not able to unlock CDL with the shifter. The lever does not move far enough to turn the cdl bolt far enough. If I pull the connector on the cable, then I'm able to move the bolt that little extra bit that is needed to unlock, but the lever doesn't move any further. Any thoughts on how I may be able to adjust/modify this shifter to work properly?

Before you bolted in the '04 transfer case lever, did you enlarge the opening on the plate that it mounts to? I used a dremel tool to notch the plate on my '00 before I bolted it in. Had I not done this, the lever wouldn't have enough travel when moved to the left.

..Or is it a problem with the steel cables bound within the sleeve?

I did cut a fairly large hole to allow for the movement. I lubricated the cylinder that is connected to the cable, and all of its joints. What could be binding up the cables? Is there a way to fix this?

the 04 locking solinoid has been removed from the shifter?

Yes and no. I noticed that, and chopped off the pin, but from what I saw, it only prevents the high low movement. Am I missing something that locks up the diff lock movement?

Did you try adjusting the cable? There is a adjustment where it attached to the bracket by the nipple. The cable is threaded with a nut on each side of the bracket.

This could be very helpful. I'll have to look at how I may be able to adjust the cable so that it is able to turn the nipple far enough to unlock. Thanks.