Are there any benefits of one years CDL transfer case over another? I know the 2004 has the ideal cable shifter. Is there a reason to use one year vs another? I was originally planning to use the D1 shifter but found the 2004 t-case for the right price.

I currently have a "shot" 1999 t-case with CDL(without shifter) @199,000 miles;
Picked up a good 2000 t-case with CDL(without shifter) @85,0000 miles;
Nabbed a 1996 D1 CDL shifter;
Will be picking up a 2004 t-case with CDL and shifter @110,000 miles.

 

I think there's a difference between D1 and D2 in his the gear teeth were cut, but as far as between years of D2 I think the only difference was CDL or no CDL.

All of this is third hand info, though, so don't hold me to it.

 

I'd use the 2000 transfer case (less miles), with 04's shifter...if that is the question. As far as the internals of the Dl and Dll, I've got nothing for you that will hold up in a court of law...lol.

Brian.

 

I put an ‘04 shifter into my 2000, with original transmission. The D1 shifter required a little modification to work in the D2, so I opted for the simple route and went with the cable linkage. As I recall, I had to remove the lock-out solenoid from the body of the ‘04 shifter, since the 2000 transmission carries the neutral lock-out internally and the ‘04 doesn’t, though I may be mistaken about that. It all happened some time ago.

 

If you choose to keep the TC mounted interlock then yes you must bypass the 04 setup. I personally prefer the 04 setup as it's easier to get around if it fails out on the trail. With the 99-02 setup if it fails you are stuck in whatever 4wd range you were in unless you tear off the interlock solenoid housing and remove the guts from the solenoid (not trail friendly). With the 04 setup if it fails you can reach up externally with a long rod/stick and bypass the solenoid and get into whatever 4wd range you need.

On my 02 Kalahari I made a blank steel plate, and got 4 shorter screws and completely removed the interlock on the TC (it was stuck in 4Hi). I used some RTV installed my plate, along with the shorter screws and then installed my 04 CDL Linkage and just plugged in it's interlock solenoid to use in place of the original unit.