Hendo's factory look CDL for D2

**Hendrik** · 17th February 2010, 11:01 PM

Hi All
After using an underbody lever type cdl for about a year, which worked great especially seeing as I used a 10mm spanner before then, which certianly isn't fun as most D2 owners can tell you. So after a bit of research and playing around with some ideas and being unable to find a factory one, I attempted to convert the old D2 Hi-Low lever into CDL lever that will function exactly like a D2a style CDL.

So out came the Hi-Low lever and I took to it with a grinder with a really small disk. The underside of the housing had to be removed in order to make room for the side ways movement of the lever.

Then after using a bit of trial and error I came up with this, sorry I got a bit distracted as I went along and forgot to take some more progress pics.

Then made up a little bracket that bits onto the transfer case that holds the cable in place:

I had an old cable laying around the shed that I used, and had to modify slighly by shortening it and welding the threaded rod back on, in order to make it fit properly.

Here is a pic of the cable installed onto the front output housing:

After a bit of fiddling around, I got it to work, and it works beautifully, just like a factory one

And the best thing is, it did not cost me a cent...so happy with the result. Now I can lock the CDL in high or low range without getting out and best of all it looks factory like it should

Will post up some more pics tomorow when I have it all back together and neaten up the installation a little bit.

midal · 17th February 2010, 11:35 PM

Sounds great Hendrick, looking forward to the finished pictures.

Cheers
Mick

**Shamo** · 18th February 2010, 01:19 AM

It's a shame that your car isn't going to pass roadworthy when you try to re register it! but good try anyway! Perhaps sell it on ebay?

Shamo

**Urban Panzer** · 18th February 2010, 01:25 AM

Originally Posted by Shamo

It's a shame that your car isn't going to pass roadworthy when you try to re register it! but good try anyway! Perhaps sell it on ebay?

Shamo

Why would that be the case ?

I think its a smashing DIY job tbh, and if it works, then great!!!. The only "issue" for me personally would be the bottom of the lever is "open" to the elements (like the new ashcroft ones) so in a big swim you may get water into the tunnel area, apart from that, thumbs up m8!!

**Redback** · 18th February 2010, 06:31 AM

Originally Posted by Shamo

It's a shame that your car isn't going to pass roadworthy when you try to re register it! but good try anyway! Perhaps sell it on ebay?

Shamo

To quote a famous Australian, soon to be England bound

Please explain??

Great work Hendrik

Baz.

**stig0000** · 18th February 2010, 06:52 AM

looks allrite ay,,,

**Hendrik** · 18th February 2010, 08:56 AM

Originally Posted by Urban Panzer

Why would that be the case ?

I think its a smashing DIY job tbh, and if it works, then great!!!. The only "issue" for me personally would be the bottom of the lever is "open" to the elements (like the new ashcroft ones) so in a big swim you may get water into the tunnel area, apart from that, thumbs up m8!!

Yes that did cross my mind. I've thought about getting a rubber boot and placing it on the underside, as well as on top where the retaining plate goes, that should keep some water out. Considering on the manual models the only thing keeping water out of the tunnel is a piece of rubber. So hopefully that works

**disco_thrasher** · 18th February 2010, 02:31 PM

Awesome Hendrik
You and Shamo are like a married couple

**Shamo** · 18th February 2010, 06:25 PM

<3 <3

**disco_thrasher** · 18th February 2010, 07:58 PM

Originally Posted by Shamo

<3 <3

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