yes, sorry, out put of the tranny is 25 spline, not the t-case going to edit right now.... <img src="/forums/images/graemlins/drunk.gif" alt="" />

there will only be one chain.

and- the point of all this is to get lower gears. there is an easier way than complete fabrication from scratch. why not take it?

one more thing- getting tires this next weekend, used TSL's just to get me into next year or so.

as soon as i have some extra cash for the zuk tranny and the adapters and toy t-case(s). i'm going to get them one piece at a time, put it together nice and slow and drop it in. so, be done around x-mas, i hope.

that sounds awesome dave, good luck with the swap hope everything works out with this.

from the sounds of things though there is no "easy" way for those of us with the manual transmissions at the moment though. But what got me thinking is you said that there is adapters that would bolt up to the end of the transmission allowing us to make use of other transfer cases? did I understand this correctly?
because if that is the case I may have to do some talking with my dad about making a custom output shaft that drops down to the required 21 or 23 spline shaft for use of a different transfer case.

the adapter shown above as well as one made by OTT will bolt to the automatic tranny, not the manual tranny. what i was hoping is that someone would do some research into what other vehicles have used the same manual tranny, so we might be able to find another transfer case to fit it, or, another vehicle to donate a tranny/t-case set-up, just retaining the Kia bellhousing, as we will be doing with the auto.

and as stated previously, all you need as it is to run any t-case you want behind a sportage auto or manual is a 2wd adapter on the tranny and short driveshaft to the t-case and probably a new support x-member for the t-case.

anybody know if any other vehicle on the planet used the Sportage manual tranny?

Couldn't you use a 5 speed from a 2wd Sportage and use a divorced transfer case?
Everet <img src="/forums/images/graemlins/patriot.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" />

well, yeah, but you could do the same with an auto, run the 2wd tranny and a divorced case, however, if there's the chance of not having to deal with another driveshaft, 2 more u-joints, a whole nother mounting x-member and the added length, why not try to find the way?

see, you have to keep the tailhousing, which is the same length as the stock t-case, so, you'r basically already starting with your added length behind the current position of the stock t-case.

i think you'd end up with a pretty short rear d-shaft in the 4-door and almost no rear d-shaft in the 2-door.

so, let's try to find out what other 4x4's in the world ran these manual trannies, or at least one with the same bellhousing bolt pattern and input shaft dimensions.

Dave,

Yankee Bob was over last night (He's a 20year Toy master tech). While applying POR15 to the axle housing were are building, we got onto talking about the GV, the 4spd auto and alternatives to the OTT Kickers.

He's saying that he's 90+% sure the same 4spd AW tranny appears in some year XJs. If true, this opens more possibilities for you, and others. He's going to check.

As for the R&Ps, not good words. The front rings fit, and do the pinion with minor machine work, but get this, the ring bolt holes do not. He's going to have to clock the gear, drill and tap (real fun in gear steel).

He's found nothing for the rear. GRRR!

He hasn't put a lot of time into it. Kinda me call and a fire is lit which burns briefly until I call again. If he figures this all out, AND produces some sets, i got a feeling it will be pricey. Should he give up (possible), I'll ask if its okay to devulge the donor auto for the front R&P, and let folks go from there.

See ya all around soon. Haven't done much Kia tinkering (the new-car thrill has subsided) and I'm almost done with the 2006-07 winter build up of my Sammy, just in time to start the 2007-08 build. The older I get, the slower I go.

actually, i think i might ahve heard that before too, i'm gonna check into it.

***edit

and a while later....

i can't find a dang thing, nada....

And people look at me funny when I crawl under there 4x4s in the parking lots. <img src="/forums/images/graemlins/lol.gif" alt="" />

heh, yeah, i used to do that, too.... <img src="/forums/images/graemlins/scared.gif" alt="" />