Hello! have been reading posts here for a while but finally time for me to break something of my own and have to make a post myself lol

I have a 2003 discovery that had a bad transfer case, it was clicking and leaking profusely so i decided to swap it out with a transfer case that has the diff lock feature. I found a known working unit on facebook from a 2000 disco and set off. I have removed the old transfer case and installed the replacement, swapping the tail shafts and one of the plugs, i believe i can wire the high/low electronic switch that i am now missing to a switch and just flick it when i engage low range.

I put pretty much everything back together (all plugs were back installed with the exception of the cigarette lighter and said high low switch) And the truck starts and then dies immediately afterwards, if i crank it a second time it will run for fifteen seconds and then die, this repeats.

There's no damage to wiring as i removed it that i can find, no engine codes, and no blown fuses. I'm a little baffled as to why it wont run, i tried switching the 02 sensor plugs and unplugging and plugging back in everything i had touched (just the plugs above the transfer case) and i would love any suggestions anyone has as to why this is occurring.

 

If you try driving the car within that 15 seconds, does it die when moving?

 

CPS will shut of the car when it gets hot. I would think it is unrelated to the transfer case, but maybe a wire got bumped, or dirty or other? How long does it run from stone cold?

 

I've swapped a couple of transfer cases. I don't think there is anything electronic that will cause an engine shut-off.
There's also nothing related to the hi/low range that would need an external switch. That system is common to all years of the Discovery so the switch that notifies the various computers is built into the transfer case.

 

starts right up, dies right away, and then on the second attempt at cranking you get 15 seconds (give or take a few seconds) of running before it shuts off. Seems to be an electrical shutoff as it doesn't sputter just stops. Would there be any cps wiring near the transmission or transfer case i could have bumped?

putting the vehicle in gear causes it to die right away

 

You have fuel lines running in that area (above on chassis rail) and also have that canister mounted on the inside chassis behind the t-case. I would make sure you didn't damage any lines/connections. Might explain why your cutting off after 15 or so seconds.

 

Maybe just a weird coincidence, but the '94 D1 did that when the alternator failed. Does the battery light go out? Does the tachometer give any reading? If no, could be a bad alternator.

 

I figured something out! one step closer, thank you for all the suggestions. I checked over the fuel lines and all wiring in proximity when i got home from work but it seemed to be a transfer case related issue? combined with the intake coming off lmao

I started it, it shut off immediately, and during my second start where i got 15 seconds of runtime i quickly shifted the transfer case into high out of neutral and the transmission into reverse. I believe something was not in alignment and the transmission wasn't happy as there was a small clunk/grind and now all is well, it runs and idles as it should, shifts smoothly all around (something in the transfer case could have also been stuck). That combined with the intake hose somehow popping off after the MAF made a whole lot of chaos and error lights for something that now works perfectly. Step one of diagnosing an issue should have been look at the engine but i was too focused on the area i had messed with.

does anyone have info on wiring a transfer case from 2000 up to a 2003 saved up? location of the diff lock wires in the harness (if any to light up the dash) and getting the neutral safety properly working and such.

 

When I did my swap I noticed you could use either of the switches on the top of the cone to work or use them both and you dont' have to ground them.

 

Thanks for the write up! And yeah i figured out this morning the correct order of wires/plugs but that pdf is awesome for getting the light on, Cheers.