Doesn't somebody on this board run a "dual transfer case" setup? I've searched the archive for postings on the likely suspects: dual, twin, divorced +tcase, +transfer; can't find it.

Looking for data to help analyze the possibility of divorcin g a manual case, which I'm currently blessed with too many of.

Any pointers appreciated.

--f

NathanC does.

Post

1 bad <img src="/forums/images/graemlins/butwiggle.gif" alt="" />crawl ratio.

lordtrunks is putting dual divorced t-cases in his pickup.

Nathan's --
http://www.4x4wire.com/forums/showf...&o=&fpart=1&vc=1

F - I spoke to the guy that's doing my adapter now about this a couple weeks ago and did some prelim research.

Issues we came up with:

1) Over all length of the completed assembly.

2) 'face plate' or 'cover' or whatever you want to call what needs to enclose the front of the t-case - what is normally kept free of dirt and crud, etc. by the tranny->t-case adapter/housing.

3) Some kind of yoke/flange assembly for the t-case input.

4) Drive assembly between the tranny and t-case.

5) A way to mount the transfer case in the vehicle.

6) Two wheel drive tailshaft and shift assembly.

OK. #2 isn't that big a deal - probably the easiest part. and #5 probably isn't either - although I admit I didn't get that far in my thinking.:-) #4 isn't that big a problem either - not like its never been done. Stuby driveshaft with a Mitsu joint on one end and a ??? on the other.

#3, however, I'm not so sure about. In theory - IF I remember correctly - with the NP231, it should be possible to do a reverse of what I did to my t-case output yoke. Build a yoke with a splined shaft that fits inside the input collar of the t-case. Drill the splined input shaft to receive a bolt run through from inside the housing through the center of the planetary gear unit and into the new yoke. I can think of several ways to design the new 'yoke' that'll allow for a seal between the new 'yoke' and the new 'cover' - nothing real special there.

That really leaves #1. This is what stoped me from doing this.

(metric sizes measured with an American ruler so they're not to the mm <img src="/forums/images/graemlins/smile.gif" alt="" /> )

The Mitsu 5-speed is 11" long. The tail housing/adapter to the t-case is 5" long. My new Mitsu trany to NP231 t-case adapter will be 7" long. I had the super short TerraFlex SYE installed in my NP231 to reduced the NP's overall length by about 6-7". Given the above, the overall length of the entire new assembly - trany, stock housing, new adapter, NP231 - will only be 2" longer than the stock Mitsu assembly.

Anyway, I'm almost certin that the 2-wheel drive tailshaft housing is longer than 5" - but figure 5" for the sake of argument. You'll need something like 2-3" for the face plate/cover thingy for the input side of the new t-case. And, you'll need another, what, 10-14" in the middle for the drive section - stock slip output yoke -> short drve shaft -> u-joint/input yoke?

So, figure 16"+2" of fudge factor = 18". So, if you measure back 18" in a Montero is there room to still bolt in a transfer case and clear the torsion bar cross member? The tunnel? I know I don't have that kind of space in my Sport. Which is one reason I opted to go the adapter route. That and I don't think this is any cheaper or easier.

Be nice to hear other opinions, though!!

Edward

run the driveshaft under the crossmember this is what a divorced dana 20 looks like under the 79 mitsu pickup with the km132 2wd manual. I'm hoping my km148 which is currently mated to a bronco Tshift dana 20 will fit which it should it measures 38-39" total I won't know till i can get under the truck and thats gonna be a few months if not i'll just get the 4:1 gears for the t\case.

Yea, that's what I thought for the front but what about the rear crossmember where the torsion bars attach?

Edward

Why not cut the torsion bar crossmember off and have a new bolt on crossmember made up that will also support the new t\case

I'd thought of that with my Sport but I wasn't sure that was a good idea nor was the shop that did my SAS. That is a major frame structural member as well as the support for the torsion bars and there was some question of whether a bolt on cross member would offer the same support. We were fairly sure we could build a cross member that would handle the stress, but.... I get a little paranoid about hacking stuff like that out of my frame. <img src="/forums/images/graemlins/scared.gif" alt="" />

Edward