I have a feeling that most members who actually do this kind of swap are using front output assemblies from earlier DII's rather than DI's.

 

Richard, you're spot on with regard to the DI front output assembly and the DII front propshaft. If one chooses to use a DII front propshaft on a DI they would also need the front output flange from a DII transfer case as well. It is larger than the flange on a DI LT230. I just sold someone a DII shaft and flange for this very purpose.

Now, going the other way, while I don't know why someone would, installing a DI front output assembly would necessitate the use of the DII front output flange to enable fitment of the DII propshaft. Mechanically this will work but, again, there is the issue of the hi/lo detect sensor and how it informs the engine ECU and transmission ECU along with the BCU. I can't recall anyone I know going this route so I can't speak from experience.

 

One last thing. If anyone is need of an early DII transfer case or output assembly, I have them. If anyone is interested in the final incarnation of the LT230, the venerable 2004 LT230SE with the nipple, I have one of those as well. PM me and we can tall about prices.

 

Not wishing to hijack the thread, but has anyone lifted down an LT230 on their own below the truck whilst on axle stands. I am considering doing this but it weighs 55kgs. I am considering buying a motorcycle lift, either scissor type or hydraulic and a used angle milling table in place of an LTR-99-010 bracket. I'd be interested to hear of others experiences.

 

The best thing to do to handle both the weight and awkwardness is to take the transmission brake assembly off. Right there you lose about 45 pounds. Then the transfer case weighs about 100 pounds and it much easier to manage on your own. To remove the brake assembly you have to first take off the screw securing the drum, then the four 15mm bolts holding the backing plate to the transfer case main body. It take five minutes and makes a world of difference.

 

What about one of the small scissor type transmission jacks on wheels? they go up pretty high. not sure how high you have it on the stands. If you have anything like harbor freight over there, they carry one for pretty cheap $.

 

I use a transmission jack, no adaptor plate.

 

yeah, i heard it was a long dirty, difficult job. i was hoping to just transplant the front output flange but since there is a chance that the internals are broken, looks like i will be doing an entire transplant. i was hoping someone had a similar experience with their case and it was either remedied by the front output transplant or something as simple as an internal linkage...based on the fact that it is stuck in low, i am beggining to think that it is a shift fork or selector. looks like i will have a couple long weekends ahead of me!

 

Thank to all you guys. I'll remove the parking brake assy first and use a scissor lift and then lower it down ........... carefully. If I don't post on here again you'll know I dropped the ba___rd on my head and I'm with the fairies . ................ not that it could do any brain damage in any event