I'm about to install a 2004 DII CDL selector lever into my 2001 DII which fortunately has a "nubbed" D42 transfer case.

For 2004 the interlock solenoid was moved from the main casing to the lever assembly, which I realize now leaves me with 2 interlock solenoids! Admittedly I haven't taken the original selector out yet to take a close-up look. Anyone else run into this and what was your solution?




2001 Transfer case with interlock solenoid in case.



2004 Transfer case with interlock solenoid on selector.

 

Remove the duplicate interlock from the '04 linkage, easiest way to resolve your situation.

 

Yep ditching the 04 interlock is the easier way, however I like it vs the unit found on the older TC's. The other unit when it fails gravity is it's worse enemy & you'll be stuck in 4Hi or 4Lo with no real quick fix route vs gutting the console to try and gain access to it or removing the Ebrake Drum & blindly trying from the bottom.

If it was me and you're already gonna have the console out I'd bypass the interlock on the TC & go with the 04 unit which is in a much easier spot to work on & I've been able to bypass one out on the trail a heck of a lot faster than the 99-02 interlock.

 

Good advice, much appreciated! The easiest way definitely appears to be removing the interlock on the 04 selector and leave the existing one as is. The 04 interlock is definitely is more accessible though, you would probably be able to get a hand on it from underneath if it fails.

To bypass the existing 01 interlock, I assume I would have to remove the solenoid from the housing as it locks when not energized?? I should probably do a DIY on this to help someone in the future.

 

Yes to disable the 99-02 Interlock you must remove the inner pin that moves up & down inside the solenoid. I simply removed the entire unit, then I replaced the entire assembly with a flat metal plate I had. I just marked the 4 holes from the old unit drilled em & used RTV and 4 shorter bolts to install it.

Another way I've seen is to take #5 completely out and place it in a vise and drill out the solenoid pin from the back, then afterwards make a small circular gasket in the shape of the #5 part and place it under it with some RTV, then re-install everything and use RTV on the outer cover plate as well.

In the long run you will be better off and yes you can get creative and reach it much easier on the side of the trail/road vs tearing into stuff on the 99-02 setup.

I did all of that when I slapped the 04 CDL & SLABS Unit into my 02 Kalahari since I already had it torn down installing the CDL in the first place.

 

Any benefit to switching out the 01 SLABS ECU with the 04 unit? I can still get it from the 04 I took the shifter out of.

 

It will give you a complete 04 setup, and no issues with shutting off the D2 with CDL engaged. Better programming is on the 04 SLABS as well for ABS & TC.