I'm finally getting around to putting a D1 CLD arm into my 2001.
So far so good.
I've got everything out. The old hi-low cable snapped just as I was taking everything apart. Knew it was about to go, so that was as good of timing as is possible.
I'm eliminating the cable entirely. I am a little worried about what's going on in the middle of the cable as it comes back around (see pict). There's some wiring that looks like it might be involved... I don't think there's a switch there... but... Pretty sure hi-low is detected in the transfer case, not at the cable. Maybe neutral detector? Just want to make sure that not having it doesn't come back to bite me on the ***.
On the D1 Selector... what's the "fat bit" on the the actual shifter stick (see other picture)? Anyone know how it works? I tried unscrewing it, that doesn't seem to be a thing. There's a hole in the side... I've prodded around in there. Seems to have rubber in it... doesn't seem to have any kind of release...
It would be really useful to be able to move adjust that for two reasons: to get the fitment of the cover plate right without having it in the way, and because it leaves very little clearance between itself and the plate. Like less than a millimetre. I feel like it's going to hit the plate and force me to cut out way more than would be needed for just the shaft.

Anyhow... I'll update as I go.
Been using the standard instructions: www.discovery2.co.uk/Factory Diff Lock
Except now I'm into the D1 arm instead of the 2004. Kind of making it up as I go.
I'm going to have to make the actual nipple plate and the final connecting metal U as mine didn't come with... I think that will be easy enough... just going from photos. If anyone had one the felt like shooting from straight down with a ruler... I wouldn't complain.

I did have to remove the transmission cable - can't see cutting the hole out in the truck.



Cable Question.

What is this damn thing? And why is it so large and low?

Just progress.

D1 Arm.

 

It's this U and the plate that I don't have. Going to just make one out of brass...
Anyone with measurements... would be very helpful.

 

Also could use a better picture of it... I had one somewhere, but damn'd if I can find it.

Also if anyone knows the specs of the four bolts that attach the d1 assembly to the top of the transfer case... Would save me searching and guessing.

 

The shift cable is bolted to the transfer case down behind those electrical connectors, but there is nothing else going on there. The later year trucks do have a wire inside a wrapping along with the shift cable but it just goes up to the interlock mounted on the shift lever itself.
There are four 10mm bolts that hold two plates onto the top of the transfer case, plus a larger one (I think 14mm) for the breather pipe. If you remove those bolts, the wires and connectors and the shifter cable should all be much more accessible.

 

go to this page and get the parts numbers. If you click on the part on the image, it will link to the part, maybe you can order them from rovers north or aschroft. Ashcroft has super fast shipping to USA. Brass is OK, but obviously, steel is stronger......if its not listed, at least you can get the part numbers and search for it...

https://www.roversnorth.com/category...levers_linkage


also this: (diff lock arms may be the same so maybe you could use a D2 arm?:
http://www.discovery2.co.uk/D1_to_D2_cdl.html

the 'big fat' part on the shifter shaft is probably a left over design from years back. the hole may be for a fixing pin.....

 

Thanks guys.
Just have to share my first victory...
I can articulate the centre lock!

And brass. I know, not ideal, but it’s what I’m equipped to work in.
I figure it’s not something that has to last thousands of uses. How many times am I really going to get to use it... twenty year old truck... I live in downtown Toronto... 20 times if I’m lucky.

 

Doing okay...
Got the lever in and can move both high low and centre lock. Only had to go up and down the stairs 16,000 times...

Now. Putting that plate back in...
Doesn't look to me that screws on the new lever line up even remotely with the old holes.
How on earth do I locate those?
Baffled by that prospect.

 

Ah. Turns out I don’t. They are below that plate. Just the lever comes through. Now it’s mounted to the transfer case it really doesn’t need them.

I’m not 100% on this, as it’s still very disassembled — she doesn’t seem to know if she’s in high or low right now. Can’t remember what happens dash light wise, but I thought something happened. Hill decent just flashes and beeps....
Any chance I’ve disconnected something critical? Or otherwise kiboshed it?
Just a thought before I rivet it back down.

 

Hill descent only works when you're in low range. If the dash light isn't coming on when you shift, it seems likely that hill descent won't engage because the system doesn't know it's in the correct gear.

 

My thoughts exactly. Wondering what I've done to make it stop working...