I just reassembled my '00 disco yesterday from doing a similar swap. I used a D1 TC and shifter. I did not swap the switch, and am thinking about going ahead and doing that too. When I took it for a test drive, in high gear, it was very loud, and it would not shift into low. When I tried, it acted as though it was in neutral. Do I need to do some adjusting to the shifter so it will actuate the low gear? At help would be greatly appreciated!

 

My guess is that, if you did not use the hi/lo cover from the DI transfer case, you probably need to do some adjusting to the linkage.

How did you make up the gap between the end of the hi/lo rod on the linkage and the arm coming out of the hi/lo cover on the transfer case? Did you bend the rod? If so, you've changed the throw and will need to adjust the linkage to make up for the shortening that occurred with the bend.

Wait, I'm rereading your post. You used a complete DI transfer case with the DII?

 

I used a transfer case and shifter from a '96 d1 in my 2000 d2. The linkage connected right up. It appears to switch over when I throw the shifter, as in it makes a clicking sound as it does when you shift out of low, but when in low, and I shift the tranny into drive, I acts like its still in neutral, in fact, as I revved the engine, I started to coast backward as I was on a small incline. My buddy I got the TC from says he's pretty sure the TC was working fine before it was removed from the D1.
It's also quite loud when driving it in high, I'm hoping that changes if I'm able to get the low gear fixed. I haven't had it up faster than about 25-30 yet, can't imagine what it would be like at highway speeds.

 

Excellent write up BrandonS, an innovative piece of engineering perseverence and good result. Yep, there are easier ways but you achieved all that you wanted. Commendable.

 

how do I save to follow a thread like this thread so I don't restart discussion like I'm doing now lol I have an 03 and curious as Ive heard some 03 in the wild did have the CDL in place just no linkage but as a rule of thumb 03 did not come equipped... anyway.. how do I check? I may have some transfer case issues at moment and if I have to replace ir or change something I may just do this...