Thread: Clearing D4 aux battery tray

Here's what I did to relocate the control modules occupying the D4 aux battery tray.



The transfer case ecu was removed from its plastic cover. The ecu is still unsealed same as in the D3 and the cover only prevents dust or water from spilling onto the ecu but not from entering the cover from the bottom. The glow-plug ecu was unbolted from its metal bracket. Both the plastic bracket/cover and the metal one were not re-used.

The alarm horn bracket was temporarily removed and the short horn bracket removed from the main bracket. The wings on the main bracket were flattened (more or less) and an unused bolt stud was cut-off.

The TC ecu bolts directly to the flattened horn bracket using existing holes. 2 bolts and nuts are required.



The horn is bolted under the lower brake line bracket bolt using one of the longer bolts from the discarded plastic TC ecu bracket, along with a spacer between the short horn bracket and the brake line bracket giving clearance to the turned-up edges of the brake line bracket.



The main horn bracket now with the TC ecu attached is refitted to its original position. Some additional insulation tape was used on the wires close to the connectors to prevent possible chafing on the metal bracket.



The glow-plug ecu is bolted through the hole in the engine side of the box where an unused white plastic clip was fitted. It requires a washer.



The large harness connector was temporarily unplugged to remove twist, then the harnesses and connector cable-tied into a group.
The brake lines from the modulator were rotated upwards a little by very slightly loosening the nuts as 1 pipe intruded into the battery space.
The plastic ribs at the bottom front of the tray were removed using an angle grinder. The plastic spacer along the engine side lower edge will also have to be removed to get clearance for a 175mm wide battery.

Originally Posted by Disco4SE

Hi Graeme, mine is also an 80 Ah. I have just found out that the battery is a dud as it is not holding charge, so my auto elec has ordered me an 'Optima' battery also with side posts. He highly recommends this battery.

Hi Disco4SE. I recall you had some pic's when your tray was cleared. Can you provide the detail on the posting ? I can't seem to locate it. I still favour fitting the second battery in the old D3 location, and would like to compare the two that have been cleared so far.