Alright, I've made some headway on this deal. I've locked the case into 4wd and cut the 4wd parts out of it (so now it is locked in 4(2)wd forever. That should allow me to switch back and fourth between hi and low. I have cut case so that it has more clearance for the front drive shaft (that looks to be an issue). The hole is being welded up as we speak. I'm going to try to put a fill and a drain in it seeing as i cut those out.

Ongoing issues-

A) I belive it is going to clear the gas tank but just barly, we will see.

B) the exaust y-pipe is going to have to be removed and something new put in its place, we will see on that one too.

c) The seal where the yolk used to be.... will that now leak? What did you guys do to resolve this issue?

D) Without getting the transmission in place i won't know on this one, but i belive that the new placement of the front driveshaft is going to have to go right thru the crossmember which holds the transmission.

E) The shift lever for the 2nd case. I think i can modify the origianl shift lever for the case by welding on a long extention horizontally so it comes out the original hole. Can you guys see any problems doing this? If i do it i think it would be more of an up and down shift, but should be alright.

Any suggestions on these issues would be appricated. I'm still holding out hope that I can get it ready for moab, but alas it is fadeing from view quickly.

as far as the extension from the rear case, we did exactly what you are talking about. we did have to bend the extension a few times to get it right though.

The front cross member will need to be worked over or replaced. My crossmember is gone and a new one is adapted to the adaptor that holds the two cases together.

The rear yoke on the front t case is what was leaking on mine. To eliminate this, I just stacked another seal on the back of the existing one. No leaks since. Chad cut the threaded part of the shaft off so his second case would slide further over the existing shaft, his also has no leaks.

Thanks! I am glad that someone out there has an idea about which i speak! HA HA HA

Well, i got the tranny all welded up and it looks great. Mounting plate made today, but alas i didn't have any help to put the transmission in the car today. So it looks like maybe Monday before i can test fit things. grr... sometimes the easy part of the project takes forever!!! I did cut off about 1/2" of the output shaft so that i could get better engagement. But I'm not sure i cut enough off to stop the leak from the back of the tranny. I was thinking about cutting a section of the original yolk off so that i could slide it over the output shaft to seal it.

Only a few things left to do-

1) measure for driveshafts and get mine altered.
2) make the cross member
3) Wiring, and reconnecting
4) Modify front crossmember
5) Fab up the shifter
6) get the exhaust re-done

I still think i can get it done in this next week, but i am going to need some help i think... humm wonder what Aaron is doing...

So, I've made some progress. I've been making the mount for the adapter plate. Last night i mounted the whole thing in the truck. It was close. VERY CLOSE. But it does fit. Has about 1" of room on all sides and works wonderfully with the gas tank. Instead of making a cross member i decided to make a piece that goes from the front cross member to the rear. I don't see any blaring issues with this, so i hope it works well. It was a bear to get in there, and had to come in from the gas tank side in order to fit. But i actually think this might work now. There are still a lot of smaller issues to work out (such as the modification of the front cross member) but seeing it in the tunnel actually puts a light at the end of the tunnel.

Something to note- this mod would have never been possible without the 3" body lift. There simply would not have been enough room in the tunnel for the 2nd t-case.

How short is the rear driveshaft now, Travis... and how steep is the angle of the dangle?

Randii

the rear shaft is now 39" and the front 32.5". I haven't checked the angle yet, but from my eyeball measurement device it looks doable. I don't actually have the shafts back yet, so measurements for real aren't yet possible. All i know as of yet is that the front one will go thru the front crossmember. I am going to pull it and put a 4" overpass in it. I hope it is still strong after i'm done. grr.

oh, and is it bad to have bolts leftover when your done installing the transmission? ha ha ha! (just kidding)

Well, things didn't get done like i was hoping, and it is not looking so good. My crossmember didn't get done by the weekend and now i'm not sure when it will be done. Chances of me getting to moab are getting worse and worse. I'm going to give it the college try but i'm not expecting much at this point. grr..... Without the crossmember i can't put anything together, so ...

GOt it all in. Looks good. I welded up the shifter tonight, still needs some adjusting but it is good.

HERE IS THE PROBLEM- 4wd does not work. The 4wd light blinks but does not enguage. I leignthened the wires from my original connections, i think i got them allright but there is a chance i didn't. Also i was thinking that there might be a short somewhere amongst them. These two things i will check tomorrow, can you guys think of anything else????

I think you have a slightly bigger problem now <img src="/forums/images/graemlins/scared.gif" alt="" /> Did you end up leaving it there and get a ride back?

Explanation for those who havent heard, Trav broke the 2nd t-case at the end of the last trail and was stuck in front wheel drive low range.

Trav got a ride back to denver and I believe he is making arrangements to get a trailer back to Moab and pick it up. All I know is that I was thinking I might have to put my Amigo in a garage on Saturday night so that the T-Case would still be in it on Sunday <img src="/forums/images/graemlins/smile.gif" alt="" />