So i have an odd question, i just purchased a 2003 with a transfer case issue, i have taken out the console and confirmed that it is not a shifter or interlock solenoid issue, i removed the top of the high/low cross shaft housing in hopes that it was a sheared hi/low selector finger. It was not, as such I fear that maybe there is some internal damage to the T-case. I have available a 1995 t case from my old disco as well as a replacement 2003 t case that the previous owner threw in as part of the deal, would it be best to simply replace the t case or to remove the front nose piece containing the CDL from the 95 and bolting on the existing or "new" 2003 case since in essence all the shifting components are within the front output housing. i will be doing this on my own so i would rather just do this once!
thanks for any input/advice

 

anybody?

 

i believe the 03 tcase is longer, thus not working out for you.

 

I'm not sure of the physical compatibility between a D1 transfer box and D2 propshafts, but a D1 transfer box should have a locking centre differential so you can install the complete D1shift mechanism and gain the bonus feature

 

Putting the CDL nose piece on the 03 TC is not a very viable option from what I remember. If you really want a CDL, my suggestion would be sell your 2 good TCs and buy a used CDL TC from Paul Grant. After buying a new shift linkage your out-of-pocket should come out pretty close to a wash.

 

First of all, the D1 & D2 transfer cases are the same size, and a direct fit replacement except for the hi/lo and locking mechanism. The "length" difference in the 2003/2004 D2's are in the transmission, which is longer, which requires a longer front prop shaft.

Second, you CAN just swap the CDL nose from the D1 transfer case. In fact some members feel is the better option, since it's quicker that dropping the entire transfer case.

 

I am now better informed than I was a couple of hours ago

 

yeah i knew that to be a fact, my question is since the current t case is stuck in low and it is not a linkage issue, would just replacing the front output housing and all the internals resolve the stuck in low issue?. based on what i have seen on the rave manual, it looks like the issue is most likely a selector shaft (which is in the nose) or it could be a selector fork (which is internal to the T case and as such would not be fixed if i just changed out the nose piece...so my question is:
a) change out the nose piece and hope for the best
b) add the nose piece from the 95 to the spare 2003 t case that is sitting in the back of the truck
c) change out the entire transfer case from the 95 and change out the front and rear flanges from the bad 2003 t case.
i was hoping to get an opinion from someone that had performed this task to get a better understanding of effort and time required. since the t case will be out, i will most certainly change the u-joints to the driveshafts to make them greasable as well.

just want opinions based on past member experience.
thanks all!

 

My thought would be: as a 2003, it should not have a locking centre differential. Therefore, I'd swap the whole case over (as long as you're sure that the D1 item is OK).

It could just be that your current one could be fixed by swapping the nose - or maybe not, and it would be a shame to have to do it twice.

 

Mechanically they are the same but they are different electrically. The DII transfer case front output assembly has a different hi/lo detect sensor so there may be issues with a DI front output minus that sensor.