Ok Guys its time to sell the 2002 transfer case that has been living in my garage for over a year.
I am installing the front locking CDL output shaft on my 2003 transfer case this week. Or the next day that it is 55 or above here in Indiana. I am dreading removing the Y exhaust pipe b/c I dont want to break a stud off of the exhaust manifolds. Plus disconnecting all 4 O2 sensors will be a joyful task. Ugg
Then I will have a non locking 2002 TC case for sale with 39k on it. It looks very clean inside, as I have removed all the inspection plates.
http://www.landroverclubvi.com/di-cdl.html
Any tips,tricks that are not shown in Josh's write-up would be greatly appreciated. I have a D1 Shifter I will be installing, and have heard that it requires some bending to make the CDL engage properly. Hit me up with your experiences. I budgeting 2.5 days of not driving my Rover this week from start till finish.

Ok I have some questions:

1. This cluster of gears pulled out with the front output shaft. I see why as the "Dog clutch" which moves with the Hi/Lo selector holds all the gear in this group.
2. So, do I put this whole set in my 2003 when I do the install? I see the brass dog clutch can be removed by loosening an Allen set screw. But it is set in the correct position so it moves the gears to the HI/LO positons. I would rather not mess with adjustment if I dont have to. Here are some pictures.

 

Anyone Anyone. Has anyone done this. I'm sure your out there.
Well I answered my own question after reading the instructions further. Looks like I can put this whole gear set into my 2003 as is.

 

I am actually getting ready to do this, i found a 01 CDL, with a kit that will directly install, for 175. would this be a good time to replace the drive shaft with the greasable zerts?

 

Yes it would, You will need to remove the front drive shaft to perform the CDL install. So in about 2 days your local driveline shop should be able to rebuild your drive shaft. In 2 days you should be able to complete the project start to finish. Also you can then lockout the transfer case and run with only rear wheel drive if necessary till you get your front driveshaft back.