im preparing for the CDL install of my 96 D1 CDL into my D2. A club member recently completed this install and said that the linkage doesnt line up with the transfer case and he had to manufacture a piece to link them. This doesnt sound correct to me. I thought they would align and work seamlessely. Has anyone that has completed this mod had any similar problems? I know Cam and Mike have done this, any help would be appreciated.

 

here is a pic i do have the longer linkage piece its just not pictured. also waiting on the ****, insulation, and shifter plate to be shipped.

 

If anything, some people have had to bend on of the linkage arms, a little to make it all work, that is all I have heard.
Make sure you clean that unit completely and lube it before install it.

 

i think this is what he was referring to. but it sounded more like a good inch not just an 1/8th. thanks for the info. im cleaning it as we speak.

 

Let us know how it goes. You are going to love the extra traction you'll have.

 

yeah you have to bend the linkage that connects to the hi/lo selector on the transfer case...putting CDL in was a major PITA but I'm glad I have one now.

 

Mike did you install a D1, a D2 or an aftermarket setup?

 

would you say it was a small bend? or a large bend? did you have to use heat?

 

I wish I could help you more, but I did the 04 D2 linkage so it was just straight up... I guess this is what my mechanic was referring to when he was helping me search out linkage... He told me he would have to bend it into an "s" without the original housing. Its not impossible, just a PITA.

When I was searching for my CDL, i was saving alot of sites, both about the DI and 04 DII upgrade. Here is one about the DI upgrade that should help you:

http://www.lrrforums.com/showthread.php?p=130665

The second guy gives a link to a file, but I cant open it since im not a member on LrrF. Hopefully that can point you in the right direction. The pics in the thread can also give you a good idea of the "s" bend.

Just remember, all the work will be worth it in the end! TRACTION!!

 

small bend, I put the linkage in a vise and hit it with a 5 lbs sledge hammer...no heat. Also, be aware the D1 linkage has 8mm holes and the tab on the transfer case is a 6mm hole...I had to order some bushings from mcmaster-carr.

The major PITA part is just getting in there and then getting everything back together..you have to do this no matter if you use the '04 linkage or the D1 linkage...using a D1 linkage and buying those .50 cent bushings saved me @ $365 over using a '04 linkage....well worth the savings IMO.