CDL - photo's or drawings of activating lever

[NobbyTD5]

Hi all
I am about to fit a D2 LT 230 Transfer case with CDL
replacing transfer case in my 01 D2 Disco with no CDL..
I would like to put onto the CDL stud/activating point, a lever and bracket identical/very similar to the ones on the D2A

It bolts onto the 10MM flattened stud and cable attaches to this to activate...

Tried to souce new ones ... not available was dealers response

my RAVE has only D2 LT 203 (not later D2A) drawings etc

looks easy to fabricate but would like photos, drawings or dimensions

or would be great if people could point me to a source of a set of these..

cheers
Nobby

[Tombie]

Your dealer was full of (beep)

Lever available from Rovacraft or Ashcrofts.

Or try TriumphRoverSpares for a 2nd hand one.

Follow my link in my signature and you'll find install pics...

[NobbyTD5]

Thanks Tombie
sorry probably used the wrong words.... to describe
I am only after the bits that bolt onto the actual transfer case or to copy those

Are they available ?
otherwise will copy

Nobby

[Tombie]

Sorry mate, the brackets / cables and lever are 1 assembly.

Will answer your PM shortly, work is killing me this weekend!

[Shaker]

I currently have a genuine lever at the laser cutters, I am thinking of having more than one made, is anyone interested?

[NobbyTD5]

Shaker
which bits are you replicating ?
Nobby

[Ean Austral]

Gday Shaker,let me know what parts etc you are doing would be interested in joining the list.
Cheers Ean

[NobbyTD5]

Shaker
forgot to add to my post that I would interested as well
Nobby

[Bundalene]

Hi Nobby,

I took these pics of a Disco upgrade CDL I had recently.

URL=http://img21.imageshack.us/my.php?image=feb20a017.jpg]http://img21.imageshack.us/img21/6476/feb20a017.jpg[/URL]

http://img21.imageshack.us/img21/9885/feb20a018.jpg (http://img21.imageshack.us/my.php?image=feb20a018.jpg)

http://img21.imageshack.us/img21/7403/feb20a019.jpg (http://img21.imageshack.us/my.php?image=feb20a019.jpg)

Erich

[NobbyTD5]

The ones in the bottom photo are the ones I am initially chasing
(lower bracket and small lever actually on the TC its self)
but if a lower cost copy of the Hi/Lo lever with sideshift ( D2a style )was available then I would certainly be keen to get one..

Nobby

[Ferret]

I currently have a genuine lever at the laser cutters, I am thinking of having more than one made, is anyone interested?

Yep, I am interested if it can be done at a reasonable price.

[Shaker]

Shaker
which bits are you replicating ?
Nobby


Just the lever that bolts to the transfer case shaft, I am getting a cost at the moment.

[Roscoe]

Yep I am interested in the transfer case mounted bracket also, if you can get a price that would be great.

cheers
Roscoe

[Zute]

I'm looking at making my own soon, just with a separate choke type pull cable. But I would be interested in some pro' made parts.
Thanks.

[NobbyTD5]

Zute
Exactly what I will do given cost of gear shift lever both original and copy

have started to cost cables etc to do this and look at where to mount and put through firewall etc


was going to fabricate TC fittings but this sounds better and easier plus if Gearshift levers suddenly become available you can retro fit ...

Nobby

[Redback]

The ones in the bottom photo are the ones I am initially chasing
(lower bracket and small lever actually on the TC its self)
but if a lower cost copy of the Hi/Lo lever with sideshift ( D2a style )was available then I would certainly be keen to get one..

Nobby


What about modifying a lever from a D1, it might be abled to be modified to suit.

Baz.

[NobbyTD5]

Redback
good idea
will try to find an old one to have a good look at this
they are chepaer second hand and new
Nobby

[Ferret]

Zute
Exactly what I will do given cost of gear shift lever both original and copy

have started to cost cables etc to do this and look at where to mount and put through firewall etc

was going to fabricate TC fittings but this sounds better and easier plus if Gearshift levers suddenly become available you can retro fit ...

Nobby

Does this (http://www.boothroyd.com/cdl.htm) give you some ideas re. routing and mounting.

[sschmez]

GrumpyBastard (http://www.aulro.com/afvb/members/grumpybastard.html) from here made a manual lever ...

photos HERE (http://www.weaselsnout.net/web/pics.nsf/albums/MARR-7DZUJ7)


A quick and dirty home made Centre Diff Lock lever made from what ever i had laying about.

[NobbyTD5]

Thanks Ferret & Schmezz
all good ideas in there
I like the idea of a "in cabin" version
and that does give good hints on routing and a spot to put the knob!!
I like the idea of good fittings to the CDL so lets hope that Shaker gets a reasonable deal for multiple units - will be great

Shaker are you copying both the arm and bracket for CDL on transfer case or just the arm??

Both would be great ?

Nobby

[Shaker]

Thanks Ferret & Schmezz
all good ideas in there
I like the idea of a "in cabin" version
and that does give good hints on routing and a spot to put the knob!!
I like the idea of good fittings to the CDL so lets hope that Shaker gets a reasonable deal for multiple units - will be great

Shaker are you copying both the arm and bracket for CDL on transfer case or just the arm??

Both would be great ?

Nobby

Just the lever, I don't have a sample bracket.
I am also looking at making it about 15mm longer to make it easier to actuate if it's fitted with a pull rod or choke type cable, but all you will have to do to make it standard is drill another hole.

[NobbyTD5]

Thanks Shaker
Pity no one has a drawing or one of the brackets loose so a copy could be made

I reckon I could make one from Bundalenes photo
stud holes give some guidance to dimensions etc .. will do that if we get no joy re any drawings or measurements etc etc
cheers
Nobby

[Urban Panzer]

Are you guys referring to the bracket that bolts to the transfer case ?

this one ?
https://www.aulro.com/afvb/images/imported/2009/04/1460.jpg

If so it can be bought from land rover Part number: IGU000030

Just to throw "another" scenario in, you can use the "full" D1 setup in a D2 as well. Photos here of a recent install I did on a friends TD5

The Guinea pig motor

https://www.aulro.com/afvb/images/imported/2009/04/1461.jpg

View from below of the "correct" auto parts completed install

https://www.aulro.com/afvb/images/imported/2009/04/1462.jpg

The bottom connection on the transfer box spigot

https://www.aulro.com/afvb/images/imported/2009/04/1463.jpg

View showing the "fixed" High / Low lever connection. (here you can see the "manual version" vertical link) Does not work on a Auto box as it sits in the wrong place and requires some "fettling" to try and line it up.

https://www.aulro.com/afvb/images/imported/2009/04/1464.jpg

Picture shows the lever mounting we had to buy (bottom Shiny casting) as the "original" was from a Manual boxed car and does not fit a Auto box. You MUST get an Auto linkage for an Auto car and vice versa for a manual, how ever ALL the parts can still be bought from Land Rover if your "missing" something. :cool:

https://www.aulro.com/afvb/images/imported/2009/04/1465.jpg

And it works REALLY well, infact its easier to select the CDL than with an "03/04" linkage

[Tombie]

I fitted a D1 linkage to a D2 back in January 2000
After putting up with the NVH it introduced into the cabin for 5 years :(
I removed it and fitted the D2A lever and the cabin is so much better for it!

Not saying don't do it, just be aware that it's a little noisier.

[grumpybastard]

Thanks Shaker
Pity no one has a drawing or one of the brackets loose so a copy could be made

I reckon I could make one from Bundalenes photo
stud holes give some guidance to dimensions etc .. will do that if we get no joy re any drawings or measurements etc etc
cheers
Nobby

Its dead easy to make the hole for the cdl spindle only took about 20 mins to do and doesn't need to be very accurate at all.

You are basically fitting over a shaft that has had the 2 sides ground flat. The dimensions are approx 14mm long and the flat sides are exactly 10mm apart.

I just drilled 2 holes and then used a flat file between the 2 holes.

[NobbyTD5]

Urban Panzer
That is exactly the part I am after.. so will try with that part number in hand.... ps great photos again!

other comments and Tombie's comment re NHV are why I would hesitate on a D1 linkage

I would like to keep it close to original in dimension so that if and when a D2a lever become cheaper one day.... ( I live in hope!) I can retrofit

Nobby

PS Urban Panzer do you have the part number for the other part on the T/C, the lever ???

[Urban Panzer]

Which bit do you mean exactly ?

The small lever that actaully sits over the spigot ? if so its part of the CDL cable when referring to an "04" linkage.

I do know that Ashcroft are now making these to go with their new lever / setup...

And just for info, Both me and My friend with the D1 linkage installed dont feel its that much more noisy tbh (I wouldnt hear it over my straight thru exhaust anyway if I had one lol). I think a lot depends on how well you fit / seal the rubber boot and make sure when you cut the hole for the lever that its all well clear of everything once re-installed.

[Skiboy]

I currently have a flat bar leaver operated from outside the vehicle (under the drivers door) as a temp set up.

I looked at using a choke cable but they flex too much to push the plate on the CDL back and thus did not work – 2 cables for sale if anyone wants them!

I now have a 13 ft marine control cable ($37) which are stronger and will not flex which I need to fabricate brackets for both ends. This cable is similar to the genuine part in terms of stiffness. It will work off a leaver under the dash with cable coming via the fire wall

Will post pictures when I get a weekend to do this in

Keith

[Skiboy]

I just posted in the Technical/Tutorial section some pics and a description of what I have now set up for my D2 using a marine control cable and scrap metal I had lying around.

This may give other ideas - hope it is useful
And it works - only thing I will add is some soft rubber to keep dirt out
Keith

[NobbyTD5]

Update
Have ordered the bracket that Urban lists part number for below and it is not in stock but have ordered from UK ... Price only $10 approx 10 days wait
not worth fabricating for that!
Thanks Urban !
Cheers Nobby


Are you guys referring to the bracket that bolts to the transfer case ?

this one ?
https://www.aulro.com/afvb/images/imported/2009/04/1460.jpg

If so it can be bought from land rover Part number: IGU000030

Just to throw "another" scenario in, you can use the "full" D1 setup in a D2 as well. Photos here of a recent install I did on a friends TD5

The Guinea pig motor

https://www.aulro.com/afvb/images/imported/2009/04/1461.jpg

View from below of the "correct" auto parts completed install

https://www.aulro.com/afvb/images/imported/2009/04/1462.jpg

The bottom connection on the transfer box spigot

https://www.aulro.com/afvb/images/imported/2009/04/1463.jpg

View showing the "fixed" High / Low lever connection. (here you can see the "manual version" vertical link) Does not work on a Auto box as it sits in the wrong place and requires some "fettling" to try and line it up.

https://www.aulro.com/afvb/images/imported/2009/04/1464.jpg

Picture shows the lever mounting we had to buy (bottom Shiny casting) as the "original" was from a Manual boxed car and does not fit a Auto box. You MUST get an Auto linkage for an Auto car and vice versa for a manual, how ever ALL the parts can still be bought from Land Rover if your "missing" something. :cool:

https://www.aulro.com/afvb/images/imported/2009/04/1465.jpg

And it works REALLY well, infact its easier to select the CDL than with an "03/04" linkage

[Zute]

Was the Part number correct? As my parts guy doesn't recognize it.

[NobbyTD5]

Zute yes
my dealer had no problems with number ?
hope I am getting what I thought though!:(
he did say it was a bracket


will let you know when I get it
after Easter

Shaker any update on the other part you were replicating?

Cheers
Nobby

[NobbyTD5]

Skiboy/Keith
Great photos & tutorial thanks
got to love the (tap) handle... looks good
I was looking at a marine cable as well but shorter Whitworths have then in a variety of lengths did you need 13'?

Where did you put cable through the firewall ?? any chance of photo of that?

cheers
Nobby

[Shaker]

A diesel 'Stop' cable is perfect, they come with a 'T' handle & external cable adjustment.

[Ferret]

A diesel 'Stop' cable is perfect.

Please explain - what is it, where do you get it.

[Shaker]

Please explain - what is it, where do you get it.

Look here ..... http://http://www.fdrive.com.au/docs/FDA%20Push-Pull%20Cable%20Systems%20&%20Accssores%20Section%20pgs%2041-55.pdf

[Ferret]

Look here ..... http://www.fdrive.com.au/docs/FDA%20Push-Pull%20Cable%20Systems%20&%20Accssores%20Section%20pgs%2041-55.pdf

Linky thing fixed :p:

Thanks

[NobbyTD5]

Ferret Thanks
any code etc for the diesel stop unit ?
guide on price?
Cheers
Nobby

[Shaker]

Ferret Thanks
any code etc for the diesel stop unit ?
guide on price?
Cheers
Nobby

Ring this number & ask! 1300 36 37 35
Just tell them what you want to do.

[Skiboy]

Skiboy/Keith
Great photos & tutorial thanks
got to love the (tap) handle... looks good
I was looking at a marine cable as well but shorter Whitworths have then in a variety of lengths did you need 13'?

Where did you put cable through the firewall ?? any chance of photo of that?

cheers
Nobby
Dear Nobby
13' allows you to have wider curves going back round under the car and to the CDL - not actually fitted it yet as have been testing the whole set up and fabricating based on a transfer case on the floor - yes have more pics taken and will post when fitted in the next day or so including where via the fire wall - basically it is the bottom of the rubber boot just behind the ECU in right foot well - up and too left of the accelerator.

Tap approach was just a source of a nice round strong handle for $0 - was going to do a leaver but thought this would be more compact.

Shaker's suggestion of a Diesel Stop cable is great - these are a better design due to knob already, adjustable length at the knob end and the fact you can get different fitting fro the CDL end (I had to add a fitting).

Skiboy

[NobbyTD5]

Update 2:)
OK
visited LR Dealer in Millicent SA and..
Bracket had just arrived fresh in from the UK !
exactly the right one and I reckon at the right price
$10 ...



so Landrover part is definately IGU 000030 just as Urban Panzer quoted

cheaper than trying to copy one for that price....

just need the lever on the CDL spigot ... Shaker any update on that ??

cheers
Nobby

[Shaker]

No, I am still waiting.

[NobbyTD5]

Skiboy

Measured it up and I reckon a 10 foot cable should fit nicely
how did you go with the 13" cable - any comments before I order one

Zute did you get a bracket ??

Shaker - no luck with laser cut lever for CDL spigot ?


Cheers
Nobby

[Skiboy]

Nobby

Yeah I would go for a 10 foot - I guessed at a length in the car park and it is a little long. Mine runs around my battery then back along the side of the car and into the fire wall - it is 13 foot.

Works fine - had to make sure I limited the movement at the CDL end. I had to cut some thread off the CDL end of the control cable before I bolted the end on. Worked fine when away last weekend - the first big test at Landcruiser.

Good luck - have been meaning to post some installed photos - taken them just have to download from the camera.

Skiboy

[Zute]

No haven't got a bracket yet. Might go down to local dealer and try.
Was all set to do some fabing this weekend and put my shoulder out.
Keep up the good work Guys.

[fourteen8]

Been reading about DIY CDL linkage and found this thread. It's very interesting and really would like to know how it goes.

Any progress NobbyTD5, Shaker?

[Matman]

This is one i made myself,just thought i would post it here for people to get ideas.
http://www.aulro.com/afvb/projects-tutorials/67380-cdl-d2.html

[reid25]

Update 2:)
OK
visited LR Dealer in Millicent SA and..
Bracket had just arrived fresh in from the UK !
exactly the right one and I reckon at the right price
$10 ...



so Landrover part is definately IGU 000030 just as Urban Panzer quoted

cheaper than trying to copy one for that price....

just need the lever on the CDL spigot ... Shaker any update on that ??

cheers
Nobby

Veeeerrryyyy old thread - but how did you go with the lever on the spigot? I also can't seem to find any IGU000030's and they're all sold out everywhere which is a shame.

[admiralranga]

Veeeerrryyyy old thread - but how did you go with the lever on the spigot? I also can't seem to find any IGU000030's and they're all sold out everywhere which is a shame.

I've got one of the brackets I'd be happy to post over if you don't have any joy with a wrecker (long story short PO was very creative in getting the CDL working on my car). Re the lever for the spigot, length is fairly critical if you want to use OG cable (to make the throw and adjustment work). The fairly rough one my disco has seems to work as everything else as been modified to suit tho.

[reid25]

I've got one of the brackets I'd be happy to post over if you don't have any joy with a wrecker (long story short PO was very creative in getting the CDL working on my car). Re the lever for the spigot, length is fairly critical if you want to use OG cable (to make the throw and adjustment work). The fairly rough one my disco has seems to work as everything else as been modified to suit tho.

I was hoping to avoid making anything up (ambitious i know) but if i decide to, I'll msg you to grab the bracket off of you. thanks mate