Urgent help please! D2 transfer

[2 rocks]

Hi all
Just wondering if anyone can help?

2Rocks was/is due to have a factory CDL installed, but long story short - according to the VIN, my transfer case front output housing should have had a spigot for the CDL linkage and didn't.

The poor guys at the workshop have so far sourced 3 other housings to correct this but none have been the right combination.

What we need desperately is a front output housing for an LT230SE for a vehicle with HDC (apparently there are different switch hole sizes) and needs to have the CDL linkage attachment and detent.

(J, please correct me if I'm wrong in the description)

They have contacted most suppliers here (Perth) and in the east, so if anyone has such a thing lying in the corner of there shed...please PM me!!!!!

Thanks
Mike

[WildOne]

I did this conversion using a front output housing from a D1, no problems, i just drilled and tapped a new hole to insert the Hi/Low switch (switch on the D2 housing that is engaged when you select low range) from the D2 housing that i removed. Also re-used the front output flange and it went straight in.
I'm not sure if all LT230 front output housings are inter-changeable but it would be easy enough to check on the bench. mine cost me the princely sum of $150.

[LandyAndy]

Have you tried Linn-Rover in Welshpool???? They have a few D2s they are wrecking.
See Verhandha for contact details.
Andrew

[V8Hybrid]

Wildone
How did you go with spacing the switch out? The D2 housing has an extra bit to space the switch. If you make spacer I think there will be not enough metal to screw the switch in. We are thinking about welding an aluminum spacer on. So just wanting to know how you did it?

Julien

PS We are fitting the CDL kit for 2 ROCKS

[WildOne]

I landed up breaking the original switch trying to re-cut the thread on it for some reason (can't remember why i was trying to do this:angel:), so i had to go and buy a new switch from 4wd spares in melbourne ( i used the same type as is used to detect when the CDL is locked in) switch cost around $25 i think, Ritters wanted $70:eek:
So, to answer your original question, i drilled and tapped the housing, and used a lock nut on the switch with a large flange on it (a flat washer would do the same) to spread the load on the housing a bit.
From memory the metal where i drilled was about 5mm thick?? Was a while ago that i did the job so memory is a little hazy. If you do this conversion using a D1 housing pay attention to the pre load on the main output shaft bearing, i did the job with the transfer still in the vehicle and was a bit of a bastard, really awkward. Would be easy with the transfer on the bench.

Let us all know how you go

Cheers, Phill


Wildone
How did you go with spacing the switch out? The D2 housing has an extra bit to space the switch. If you make spacer I think there will be not enough metal to screw the switch in. We are thinking about welding an aluminum spacer on. So just wanting to know how you did it?

Julien

PS We are fitting the CDL kit for 2 ROCKS

[2 rocks]

Thanks Phill
If Julien doesn't see this, I'll let him know tomorrow!
Cheers
Mike

[WildOne]

Hey Mike,
My D2 is the same vintage as yours and also had no cdl internals, think ours must have just missed out on getting the good bits:mad:


Thanks Phill
If Julien doesn't see this, I'll let him know tomorrow!
Cheers
Mike

[V8Hybrid]

Thanks Phill. Now I can see how it was done if you used the CDL switch. Getting an adapter/spacer machined now...so let you all know how it went.
Julien

[2 rocks]

Hey Mike,
My D2 is the same vintage as yours and also had no cdl internals, think ours must have just missed out on getting the good bits:mad:

Phill
Lol! Yeah I know...but I have internals...I'd better have internals :eek::eek:

The diff lock light was coming on when the switch wire was earthing on the propshaft flange :o

Cheers
Mike

[WildOne]

If you dont have the "spigot" sticking out of the front output housing then you'll also be missing the CDL internals. So make sure your "new" replacement housing from either a later model D2 or D1 comes with ALL the CDL parts also:)

[2 rocks]

Riiiiight!
Cheers Phill :o I'll follow up.

Think I might have to get Dave to change my ID to "Lucky"...:(
Mike

[ladas]

These are the bits Phil is talking about

[V8Hybrid]

We have every thing we need. Just have to work out the housing/switch bit. Got pleanty of housings with output shafts and dog (selecter) gear ect. From my memory the centre diff housing can take the dog gear as they are all the same.
Thanks every one for your help

[ladas]

We have every thing we need. Just have to work out the housing/switch bit. Got pleanty of housings with output shafts and dog (selecter) gear ect. From my memory the centre diff housing can take the dog gear as they are all the same.
Thanks every one for your help

Good, glad to hear you have all the bits you need.