Hey all,
I have a 2002 D2 with a non-CDL transfer case. What do I need to swap to take advantage of the CDL? Do I need to swap in the entire CDL transfer case from a 99-early 01 or 04. Or do I just need to swap in the nosecone from a CDL ready transfer case?
Thanks!

 

You will need either a 99-01 or 04 LT230 with the CDL nipple, and shifter linkage assembly. I'd also highly recommend getting the SLABS Unit out of an 03-04 D2 so you get the CDL option without modifying wires, and you get the latest firmware. Some people have also successfully just swapped over the front of the transfer case, but if it's not aligned properly it could lead to failure down the road.

 

So in a pinch I can swap out the front of the case but only if I align it correctly. It would be better if I swapped the whole transfer case and a 03-04 SLABS unit though. Am I reading this correct? Just wana be sure.

 

If you can find an 04 D2 with the TC, Linkage, and the SLABS = you'd be all set without having to gut a TC. Lucky for me both my 99 & 02 had the CDL nipple so I just had to get my hands on the 04 Linkage and 03-04 SLABS. Install was quick and easy minus the rivets holding the shifter plate on. CDL with ABS/HDC/TC is a great combo out on the trail.

 

Since you really need to drop the case in order to swap the front output/locking section anyway, it really makes sense to avoid the potential alignment issues that could arise from just swapping the front part. I did both with my 2003 this past summer; I swapped in the whole case from my 1999 parts truck, but that had a huge vibration so I dropped it again and moved its output section onto the original case from the 2003 truck, which I then reinstalled. Aligning everything inside the case to install the output section is indeed tricky. I have about 1000-1500 miles on the hybrid case, so I'm still in its break-in period and am listening carefully for any odd noises or vibrations that might signal a misalignment or imbalance issue.
I have the D1-style shifter and the last version of the SLABS unit. The D1 shifter doesn't have a place to mount the CDL interlock solenoid, so the 2004 D2 shifter may be a better choice.

 

What is the alignment procedure for creating a hybrid case?

 

I don't have the list of threads that I used as references any more, but I do remember that the user named Jeff Blake had a detailed thread explaining how to refurbish a whole transfer case, including setting up all the tolerances and preloads. He had an explanation of the output section and how to align it properly.

 

Thanks for the reply. Jeff Blake has some good stuff.