Enlarging transfer case hole for CDL instal

**will_f** · 16th April 2019, 12:52 PM

Hi everyone,

So I have a D2a CDL linkage assembly on the way to instal into my 2001 D2 with CDL internals.

I'm keen to do this myself, there's heaps of instructions out there and though I'm not very experienced it looks reasonable and I'm game. Mostly!
The bit I'm unsure about is cutting the transfer case plate to allow for the sideways movement of the new lever. I've had a good search through lots of threads talking about installing D2a and Ashcroft linkages but no one has really detailed how to make this hole wider. The donor is auto and I'm manual so can't just take his plate and switch.

What kind of tool am I looking at - plasma cutter? Could you do this by drilling holes large enough for a hacksaw blade and then joining them up?? I'm guessing it doesn't have to be the cleanest job. Anyway, as you can prob tell this is where my lack of experience and crucially lack of a workshop space/equipment is going to potentially undo me.

What are the alternatives, taking to a metal worker? Just that this is going to significantly increase cost and time that the car is out of action.

Tips, tricks, past experience would be much appreciated as always. Happy to hire power tools if I need.

Thanks.

**will_f** · 16th April 2019, 01:04 PM

Confirming that a hand powered rivet gun is all that is required to lock the plate back down, rather than a powered gun?

**PhilipA** · 16th April 2019, 01:24 PM

AFAIR the hole is the correct size in an auto anyway, from when I did my 02 about a year ago.

That is for factory linkages.

You only need a hand rivet gun but there are 14? rivets.

You have to remove the shift linkages so just remember to mark the place on the cable on the transmission, and put the auto in neutral. You test the positions from the neutral position. If the light on the shifter matches with the lights on the dash in all gears you are OK.

It's a good time to put a USB plug at the back of the console if you want that. Don't put one instead of the cigarette lighter as GPS wont work from USB.
Regards Philip A

**will_f** · 16th April 2019, 05:52 PM

Cheers Phillip, although I have a manual so will need to cut the hole larger. Other tips great though, thanks

**John_D4** · 17th April 2019, 01:11 AM

I cut mine with an angle grinder and tidied it up with a Rotary tool. I found cutting it with a Rotary tool took too long

**will_f** · 17th April 2019, 06:19 AM

Thanks John yeah that makes sense I’ve only ever used large angle grinders which would blow these things apart but a smaller one would be okay. Cheers!

**Rick** · 17th April 2019, 11:21 AM

I used a Dremel and about 20 cutting wheels. It didn't really take too long. Changing the wheels took up most of the time.

**PhilipA** · 17th April 2019, 03:38 PM

I used a Dremel and about 20 cutting wheels.

if you use the more expensive reinforced cutting wheels , you shouldn't need many.

Regards Philip A

**laney** · 18th April 2019, 12:25 PM

mark out the hole size drill the corners and use a Dremel to cut between the holes this makes for a very neat job hope this helps.

**John_D4** · 18th April 2019, 11:47 PM

Originally Posted by PhilipA

if you use the more expensive reinforced cutting wheels , you shouldn't need many.

Regards Philip A

Which ones are you using Phil?

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