Thread: Almost completed CDL install...i hope

After managing to buy a disco with no CDL in the transfer case i started doing heaps of research and sppeaking to as many as i could about what is involved in installing the mechanicals in the transfer case to give me CDL.

I eventually aquired a new front output housing from Ladas (Thanks mate) and after even more time and questions i arranged two days off work to allow me to a) change all fluids and service the Disco and b) do the conversion to my transfer case.
For those of you who wish to do this at home i would like to point out the following;
1) Lying on a concrete floor for 2 days under a disco in winter is not a good idea, do the conversion in summer.
2) The difflock switch is a 3/8" thread, the high/low switch is a something close to an M12, when i tried resizing the switch and recutting the thread to a smaller diameter (which had to be done as the new housing was alot thinner where the new hole i had to drill and tap had to go, and the switch was too long) i broke the switch. So have now used a difflock switch in it's place. More logical to me to have both switches the same anyway.
3) If you're doing this for the first time it does'nt take 4 hours like the LR mechanics say it takes, it takes more like 10
4) If you dont have a veicle hoist at home and plan on doing the job on the floor (the cold floor) make sure you can stay calm whilst de-barking your knuckles and getting cramp in your arms, neck, legs etc

So on the bright side, i now have CDL in my transfer case, hopefully it works, all thats left for me to do is fill the transfer case with oil, fit a new diff lock switch in the transfer case, rewire the correct wiring to the new difflock switch (and hope the relevant warning light comes on in the dash) and figure out the best way to active the CDL from the cab.
I'm still undecided wheather to go the LandyAndy way or go for a custom cable set-up.

Pretty stuffed now so some dinner and off to bed
Adios, Phill

Yeah it is satisfying, as long as it all works okay when i take it for a test drive
The CDL works fine now so there should'nt be any problem. Now just need to paint my roofrack and cargo barrier, buy and fit a winch, winchbar, snorkel, storage ..................the list never ends

What i would give for a decent size shed with the right equipment.