CDL Lever Mod - Factory copy

**awabbit6** · 3rd July 2010, 06:50 PM

After reading lots of CDL modification threads and looking at all the options for fitting a CDL lever in my D2, I decided that I could modify the standard non-CDL lever to be very similar to the factory CDL lever.

So armed with lots of pictures (mostly from Redback's install guide

) I got started. Here's the progress so far ...

As with most projects like this, there are some things that I'd do differently next time but otherwise it seems to be going well.

The reason for modifying the original was to hopefully be able to put together a cheap kit for others to simply bolt onto their standard lever. The only modification to the standard housing is a hole drilled for the push rod.
Having said that, I don't know when I'd find time to produce them ...

I'll take some more photos of the internals when I disassemble it for some final machining. There also some more photos in my gallery.

**abaddonxi** · 3rd July 2010, 07:33 PM

And into The Good Oil you go.

So what would you do differently next time around? Enquiring minds want to know.

**awabbit6** · 3rd July 2010, 07:41 PM

Originally Posted by abaddonxi

So what would you do differently next time around? Enquiring minds want to know.

Use of different types and forms of steel, setting up to machine more efficiently and a custom made cable (I'm modifying one from the gear linkage of a Hyundai Sonata).
I'm sure there will be more before I'm finished ...

**jwb** · 3rd July 2010, 07:47 PM

great work, well done. I am sure you would get plenty of customers.

**Hendrik** · 3rd July 2010, 07:51 PM

Good stuff. Bet that was a fiddly job, mine sure was, took a lot of trail and error to make it work properly. I like how the bottom of yours is closed, unlike mine so you dont get more noise from the engine (not that I mind, love the boost sound). Nothing like locking that CDL in the cab with a factory-like lever, and done all on the cheap.

**gazk** · 3rd July 2010, 10:01 PM

Thinking of attempting something similar using a spare Hi-Low shifter cable for the CDL. Thanks for the inspiration.
Gary

**Urban Panzer** · 4th July 2010, 09:04 AM

Nice work

Keeping the bottom of the lever assy "closed" is the best idea "imo" and is what the Ashcroft lever "lacks".

I have 4 blooming old levers at home and a spare D2a one, I quite often compare them and "Look" to see what could be done

**awabbit6** · 5th July 2010, 06:56 PM

Here are some more progress shots. The lever and cable assembly is complete now. Tomorrow I'll do the cable bracket and lever on the transfer case.

Once I've tested it I'll pull it apart for paint and final assembly.

There are more photos including pics of the dismantled lever assembly in my gallery for those who are interested.

**Redback** · 6th July 2010, 07:26 AM

Mate that is brilliant, I'll bet you'll get a few requests to make some for others.

Great work, Baz.

**awabbit6** · 6th July 2010, 05:45 PM

No photos today but all the fabrication is done.

I put it all together to make sure it is working before dismantling for paint and final assembly tomorrow. It works well but is a bit heavy to use the CDL action (heavier than the Hi-Lo action) so I modified the lever on the transfer case to lengthen it and give a bit more leverage. Will see tomorrow if it has improved it.

I'll take some more pics of the final assembly as it goes together.

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