I will be getting a d1 parts truck soon and I was wondering if I can put the front output cover on and the shifter from the d1 onto my 03? Did a little research, can't find much on the d1 cover onto D2 case

 

that's what I'm about to do. just about all of the parts on the LT230 transfer case used throughout the years and models are cross-compatible, with some parts being upgraded/superceded for reasons such as gearing, noise-reduction, and tighter bearing tolerances. There aren't any differences with the front output housings with the exception of the 2004 that has 1 extra sensor where the detent spring is located on all of the units manufactured before it.


You will prob want to replace the output seal. If the output flange is scored on the shaft that the seal rides on, you will have to replace with a new one or maybe the output flange from the D2. Otherwise it will be leaking like hell.

 

The answer is yes. Swap the front output section of the case over (leave your actual diff gears in place) and the shifter will bolt on. You'll need to modify the sheetmetal piece that's under the console, but not a big deal.

 

Thanks! My plan was to do new seals and new oil. Looks like I'll be putting the front cover onto my diff. This is going to be a big project. Will I have to remove the entire transfer case?

 

No, the housing is swapped with the trans-case still in place. you have to remove crossmember, whatever it is the front housing is bolted to on the frame, driveshaft and maybe part of the exhaust.

 

Great!!! Thanks!