I'm travelling on this route again. How's the condition now considering the monsoons?
Drive Safe,
350Z
Condition of the route is good, the highway construction between Muzaffarnagar and Roorkee is on full swing and I'd recommend you to take the route only if you are passing Muzaffanagar before 8 am, else the traffic will build up causing inconvenience.
Hence the route suggestion from my side is same again:
New Delhi - Meerut - Muzaffarnagar - Deoband - Jhabrera(if you are aware of that route) else Manglaur - Saharanpaur(take the canal from Manglaur, it remains empty and going to Roorkee makes no sense).
If making an early morning travel, then take the route straight from Meerut Muzaffarnagar - Manglaur - Saharanpur.
BTW, I guess the route between Deoband and Saharanpur was also under construction, let me get its current status and return back to you.