Finally got the CDL lever in the Disco yesterday, all but the actual knob on top.
Based on the design from discoweb.org

Have attached some pics of my lever, and the U-bracket I made (with diagram I knocked up for anyone else wanting to copy).
Two other useful pics too: the "main" drawing for the concept, and a photo (can't remember where from but not mine) showing the location of the new shaft through the centre console panel.

Before I installed I wrapped the shaft with self amalgamating tape (or "weld tape" I think you Aussies call it), just to give it some added protection and also helps with reducing vibration, and packed the uni-joints with heavy duty mining spec grease.

Works a dream! Hardest part was just removing/replacing the centre console.
Job well done, now I just need to get it out there and test it!

Thanks to LandyAndy for info early on, and to all those who posted info etc on these pages. It was a massive help...

Cheers,

..:: KIEREN ::..
2000 Disco II Auto V8
Object Of Mass Consumption

Attached Images

	03052009070.jpg (29.5 KB, 120 views)
	03052009071.jpg (38.0 KB, 110 views)
	03052009072.jpg (31.1 KB, 82 views)
	cdl lever location.jpg (44.8 KB, 137 views)
	CDLDwg.jpg (25.7 KB, 106 views)

didn't realise I could only attach 5 images per post!
Here's the drawing of the bracket.....

Cheers,

..:: KIEREN ::..
2000 Disco II Auto V8
Object Of Mass Consumption

Attached Images

bracket.jpg (23.7 KB, 83 views)

That will transform the offroadbility of the Disco II once you engage the CDL. Significantly less intervention from the electronic traction control system and all stress removed for the center differential gears themselves.

Hi Kieren – that looks great! can you let us know how it is for noise & vibration pls?

The D1 used a shaft to engage CDL but mine was terrible for noise transfer through the transfer lever - it was better after I took the top off the lever and threaded 3 bicycle tyre tubes over the lever shaft.

Hi mate,
I haven't noticed any additional noise whatsover on the road, and I don't notice any vibration.
But then its not like I'm holding it when I'm driving, unlike the gear shift.
I've obviously not been off-road with it yet, but can't see it being much different tbh.

If you look at the bottom fixing bracket photo, either side of the through bolt, I put a small grommet on both sides of the socket piece to help eliminate vibration there. Where the shaft comes through the metal trannie plate there is a rubber grommet it passes through, and another one where it comes through the plastic centre console (under the rubber mat).

The two UJ's have been packed with very thick, mining grade (dust, grease, water resistant stuff) to try and keep them in good condition, so maybe some of the "rattle" has been eliminated there too? I actually spent a bit of money and bought some good quality extension pieces and UJ's in the hope they may last a bit longer!! I did think of putting some rubber (hose) pipe over the UJ's, packing full of grease, and usiing small hose clamps to hold in place for added durability. May still do this at a later date. Just had concerns over them then being too stiff and not flexible enough to get the desired angles.

Not sure if the "weld tape" contributes to noise deadening also, but it should give some more protection to the elements as its exposed under the vehicle.

Hope that helps....?

Cheers,

..:: KIEREN ::..
2000 Disco II Auto V8
Object Of Mass Consumption