1.6 engine + trans/tcase + sami case

[MuddMachine]

So since I have the room in the LWB... been thinkin. If I use this combo, where's my hi range at ? Trannies are the same ratios (or very close) then the track/kick case = 1:1 in HI. So if I stick a sami case behind this setup does my 2WD HI range stay the same as it is now with a sami tranny and t-case ? Tranny's pooched so I gotta do something and this sounds like a good thing....

:D

[MLC]

it should be the same ...that is the same set up as my tracker ...a sammmy tcase (i used a sj alittle lower reduction) behind the stock tracker case and the rears already have 513s

[MuddMachine]

This is Shaffers rig. MLC does your setup look similiar ti this ? Id like to eliminate the front output on the kick case since it wont be used.

[KAC]

I took out the t-case chain and cut off the front output off the tracker t-case for MLC.

[MuddMachine]

How did ya close it up KAC... those are some pretty vague details dude :bo:

Got a pic from the other side ? What kinda driveshaft thingy ya got goin on there ? Cant see it too good.

[MLC]

kevin did the work on the tcase he took out the chain and front out put he then cut the housing off where the output was we then had some tab welded on so we could bolt a cover on .... that drive shaft thingy is a tracker slip yoke mated to a old sj yoke iwill see if i got any better pics i will get them scanned then KAC can post them

[MLC]

it still has low range it is sweet low 2wd low 4wd double low 4wd

[MLC]

o'ya not sure i can post pics ....somebody gave me a hard time about pics of my junk being posted......lol...:boot:

[Fullload]

Yeah but i did send you a PM with donation details so that you could post pics.!!!!
The ball is in your court not ours.:beer:

[MLC]

it was sent out on tuesday ...out of my hands now ... it is up to good old canada post :bo:

[leadfoot]

I'm doing a dual t-case setup simular to Shaffer's rig. But i did away with the factory t-case mounts and brackets. They were much too weak for me so i built new ones that are a hundred times stronger than OEM. :D I'm taking pictures as i go. I'll try to post them when i'm done.

[Fullload]

Originally posted by MLC
it was sent out on tuesday ...out of my hands now ... it is up to good old canada post :bo:

The minute i get the cash Admin will be notified and your privilages will be changed.

end hijack.


Mudd if you keep both cases in hi range on the road it will not change.
What to do with the output thats left over, well if you cut the case apart so that you can put a flat sheet of cardboard or steel across, i'll feed the welder at work some beer so he can tig it all back closed for ya. or maybe you coud leave it all there except the hole (without the seal) and i could find a way to tig a plate over the old seal surface.
Thats the least of the worries. Get on to it for may 24. you'll be very happy.

[KAC]

I cut the front output right off. Then we put a plate over the hole and MLC put a bung for a pipe plug cause you lose your drain plug hole when you cut it off.

[gordZuki]

hey i got a complete 5 speed tranny tcase for ya up here if u needs to try shit with ...

[MuddMachine]

Originally posted by gordZuki
hey i got a complete 5 speed tranny tcase for ya up here if u needs to try shit with ...

Its a matter of doing, not trying :D

Where is "up here" ? I have an auto but I wanna run the 5 speed.

[MuddMachine]

Originally posted by leadfoot
But i did away with the factory t-case mounts and brackets. They were much too weak for me so i built new ones that are a hundred times stronger than OEM.

Andy did you make new arms ? And from seein your rig Id assume you have your own bushing setup as well to go with these new arms ? (I'm just assuming all this :D )

[leadfoot]

Yes i built my own arms out of 1x2 square tube and 1/4x2 flat steel. The kick trans/t-case has it's own mount or crossmember to better discribe it. The sami t-case has it's own crossmember that wraps underneath it and connects to the frame via three mounts. As for the mounts themselves, I cut off the leafsping shackle mounts from the frame and using those with rubber bushings. the kick unit has two mounts and the sami unit has three mounts, one on the left side and two on the right side. i'll never have to worry about ripping a t-case mount ever again. :D If i can find someone with a digital camera, i'll try to post some pictures.

[SuziCrazy]

Andy, I'll swing by tomorrow and capture a few for you...

[MuddMachine]

Originally posted by SuziCrazy
Andy, I'll swing by tomorrow and capture a few for you...

That'd be cool :D

[MLC]

i used tracker motor mounts for my 2nd tcase mounts

[gordZuki]

Originally posted by MuddMachine
Its a matter of doing, not trying :D

Where is "up here" ? I have an auto but I wanna run the 5 speed.

up here is back in the north for now ... u know a million miles away :-) from everyone else including my truck

[MLC]

here is a pic of the other side of my set up (if it works)

[MLC]

the tcase is setting in a piece of 6in channel like a cradle the engine mounts are attached to the bottom of those red arms ..one side is flat the other is on a 45 angle ...don't know if this helps any

[leadfoot]

Originally posted by MLC
the tcase is setting in a piece of 6in channel like a cradle the engine mounts are attached to the bottom of those red arms ..one side is flat the other is on a 45 angle ...don't know if this helps any for your set-up to work the kick t-case and the sami t-case need to be as one unit. they need to move and flex as one or else you'll have a vibration. I hpoe it works for you.

[MLC]

o it works....... run it all last year that was last years build:cool: :cool: put enough miles on it to wear my swampers 1/2 out

[MuddMachine]

So who's got a track/kick tranny in a zook ? Clearance problems ? What do I have to do to make it fit in the tunnel ?

[gordZuki]

hey i read on p4x4 that a small bodylift and no cutting ... or cutting with no lift ... if i was putting the 1.6 into the lwb i would use the 5speed i got sitting here ... but the lwb is going yota someday ...

[drtysuzuk]

does Logan not run the auto tranns in his rig?seems to work reasonably well for him. also i have an auto trans and transfercase in my trailer,not sure what i'm doing with it yet.

[Fullload]

Look into the dodge mounts like drtysuzuk said in another post. he says it drops the engine 3/4" which should be plenty to clear the kik tranny.

[leadfoot]

Originally posted by MuddMachine
So who's got a track/kick tranny in a zook ? Clearance problems ? What do I have to do to make it fit in the tunnel ? My engine/trans/t-case assembly is lowered 3" and i still had to spread the bottom of the tunnel a little. Used a big hammer to modify tunnel.:D

[MLC]

just do it ......you will like it:cool:

[Fullload]

I guess three inches is a little more than the 3/4 inch motor mount idea!!!

[MuddMachine]

Stopped in at Gordzukis place in Kirkland Lake last nite and picked up the 5 spd + tcase. THANX GORDZUKI !

The nightmare begins..... soon.

[MLC]

you won't regret it

[gordZuki]

hey T no problem man ... it wasn't being used anyways .... hope it works out

[MuddMachine]

Originally posted by SuziCrazy
Andy, I'll swing by tomorrow and capture a few for you...

We got any pics yet ? :bo:

[MuddMachine]

Ready to take this thing apart and start choppin aluminum off.

So whats the deal with the shift linkages when I pop off the back cover of the t-case. Do I just need the shifter out of the way or do I gotta fuk around with more crap before it comes off ?

[KAC]

Take the 4wd lite switch out then there is a bigbolt on the side under that is a detent spring and ball. Then down in the shifter hole there is a roll pin in the shift fork. drive that in and then you should be ready to take the t-case apart. Don't forgrt the bolt under the tranny shiter if you haven't got the 2 already separated

[MuddMachine]

Thanx dude.... off I go :D

[MuddMachine]

OK, Im doin it :po:

First the shifter off and the roll pin out.

[MuddMachine]

Once I got the roll pin out I cracked the seal and slid the case off the shifter forks or rods, whatever the fawk you wanna call 'em.



:D

[MuddMachine]

Rear view. Im off to work tomorrow morning for a few days, when I get back I'll break out the cutting apparatus and perform the amputation.

Good time for a labotomy if ya want one :ev: :ev: :ev:

[leadfoot]

Originally posted by MuddMachine
We got any pics yet ? :bo: sry he hasn't been by yet with the camera, but i'll be working on my truck this weekend so hopefully he'll come by and take some pics.

[MLC]

about time you moved this thread Mudd ......pics are great keep up the the good work

[MuddMachine]

Well it was all talk till an hour ago :D

[leadfoot]

Originally posted by MuddMachine
Once I got the roll pin out I cracked the seal and slid the case off the shifter forks or rods, whatever the fawk you wanna call 'em.



:D I used a chop saw to cut my housing. just unbolted the base from it. Once the front output shaft and chain was removed, I put the cover back on and started cutting. I cut as far as I could with the cover in place then removed it and finished cutting the rest of the way through. You just have to be carefull that you keep a straight cut. Then I drilled and tapped holes in the housing and made a cover plate. I'll try to get Suzicrazy to take a pic of it this weekend.:beer:

[MuddMachine]

Originally posted by leadfoot
Then I drilled and tapped holes in the housing and made a cover plate.

No welding at all ?

[szabotage]

I lobbed my t- case last weekend but I used a sawzall if you can imagine, but suprisingly came out pretty straight.
I was gonna drill and tap like Andy did to his but I have access to a TIG so I might as well go that route

this weekend coming up I'm building the mounts for both cases and tranny on the frame. I owe Andy a debt of gratitude
since I'm using his mounting design

mike

[MuddMachine]

Originally posted by szabotage


this weekend coming up I'm building the mounts for both cases and tranny on the frame. I owe Andy a debt of gratitude
since I'm using his mounting design

mike

Thanx for the input szabotage, if ya got a digi cam handy some pics would be kool

:D

[szabotage]

no digi but I've been taking photos since I started my new project zook, hope to have them developed and scanned soon

[leadfoot]

Originally posted by MuddMachine
Thanx for the input szabotage, if ya got a digi cam handy some pics would be kool

:D Suzicrazy stopped by yesterday and took pictures with his digital camera. Hopefully he'll post them today.

[SuziCrazy]

Here's the pics Leadfoot! www.mikelagace.com/Andy

[MuddMachine]

Thanx for takin those pics Mike :beer:

Andy looks like you opted for the straight line wich made life relatively easy. I was thinkin of doin the bottom part as well but it wouldnt allow me to get away with a bolt on like yours. I dont think the size it ends up to be should be a problem any way you wanna cut it. Here's what I was thinkin :

[leadfoot]

Originally posted by MuddMachine
Thanx for takin those pics Mike :beer:

Andy looks like you opted for the straight line wich made life relatively easy. I was thinkin of doin the bottom part as well but it wouldnt allow me to get away with a bolt on like yours. I dont think the size it ends up to be should be a problem any way you wanna cut it. Here's what I was thinkin : You can do it that way also but my way was easer to cut. It allows for a straight and simple cut. If you do it your way, you will definitly have to get it welded. With my front suspention fully compressed, my driveshaft clears the crossmember by two inches. Lotsa room:D . let me know how yours works out.

[MuddMachine]

Well I did a bit of head scratchin as to where I wanted to cut. Ive decided I will weld on a plate but my cut is straight, there's a reason for this, you'll see why in the next pic. Here's my cut line :

[MuddMachine]

Since Im a firm believer of "oil is your friend" I thought the extra space will do 2 things. First off it will hold more oil, 1/2 a liter to a liter anyways. Another thing the lower cut will do is give the sludge somewhere to accumulate. There's a good 2 inches of material below the oil gallies.

[MuddMachine]

By keeping the cut line low I got to keep my fill hole.

[MuddMachine]

OK guys, Im not to familiar with the x-member set up on the track/kicks. So can anyone tell me what the fawk the 2 mystery holes are ?

[MuddMachine]

Here's a close up of the fawkin mystery holes.

[MLC]

they are there just to make you ask questions .lol no they are for an exhaust hanger ...

[MuddMachine]

So thats the only mount I gotta deal with ???

[leadfoot]

Originally posted by MuddMachine
Well I did a bit of head scratchin as to where I wanted to cut. Ive decided I will weld on a plate but my cut is straight, there's a reason for this, you'll see why in the next pic. Here's my cut line : That is exactly where I cut my housing. I drilled and tapped a hole for a drainplug in the cover plate.

[MLC]

there was a mount on the tcase but you cut that part off the same as mine

[szabotage]

I just got my t'case back from the welder yesterday and I must say he did quite a good job. and to boot I also fabbed up my tcase mounts and got them painted in yellow so you just know its gonna add horsepower! no pics yet but are soon to follow

if anyone is looking for any tig welding in the ottawa area at an affordable price check out alcon welding, 149 bentley ave.

mike

[MuddMachine]

Im welding the Kick case tomorrow, I'll post some pics tomorrow nite. Unfortuneately I have to use the mig........

:cuss:

[gordZuki]

Im welding the Kick case tomorrow, I'll post some pics tomorrow nite. Unfortuneately I have to use the mig........

:cuss:


bout fawkin time .... just kiddin man ... let's see it

[szabotage]

came back from leadfoot's shop today and got a drain plug installed onto my newly welded t'case, now I just gotta figure out the oil qnty. to be sufficient since the original top up plug isn't the proper level with the chain drive removed.

if anyone knows how much more oil to fill after the stock top up level that would be greatly appreciated.

I also got to test out leadfoots new dual t'case setup. With 36's, toyota 4.10 or 4.62 gears(i forgot which one) and a sammi rocklobster case this thing crawls like a snail! I watched him idle in and out of a ditch, he even got out of the truck while still crawling and could walk faster than the truck! the body is really coming along too!

[MuddMachine]

Aluminum Mig..... :puke:



Comin good tho, pics tomorrow nite.

[GearHead]

are you using a new liner in you gun and sheiding with pure argon?
later
steve

[MuddMachine]

No liner Steve, it's the spool gun type. I used 0.30 wire. I just finished welding it up. Would have been way easier with a TIG machine. Because of the amperage the MIG requires to burn the aluminum I could only weld half an inch at a time to avoid warping. I used minor preheat with acetylene only. Its welded and it's sound but it's not pretty and I wont MIG it again. I'll post pics after I dress it up. :D Here's the gun I used.

[GearHead]

Nice spool gun. i need one of those.
i would not be too worried about the look of the weld as long as it is oil-tight and strong. its going to be covers in mud soon.....
keep the pics comming....

later
steve

[MuddMachine]

i would not be too worried about the look of the weld as long as it is oil-tight and strong. its going to be covers in mud soon.....


Bein a welder, Im like that. And thats why every fukn lil job takes me too long.
:bang:

[leadfoot]

Well, I got my truck back together. I have more than enough gearing. Now i have gear selection galore :D . I'll be testing it out at the PJ party this weekend. I'll let you guys know how it turns out.

[Twinkie]

Well, I got my truck back together. I have more than enough gearing. Now i have gear selection galore :D . I'll be testing it out at the PJ party this weekend. I'll let you guys know how it turns out.

Wooo Hoooooooo. Andy's gonna be there!!!!! And I may actually be able to stay close to him, not follow, but at least see where he went.

[szabotage]

Well, I got my truck back together. I have more than enough gearing. Now i have gear selection galore :D . I'll be testing it out at the PJ party this weekend. I'll let you guys know how it turns out.


dang! I was hoping I'd get the title for having the first all-zook dual t-case setup(in ottawa) but ya beat me to it! glad to hear it's working well for ya. unfortunately my truck won't be ready for the PJ, i still need a bit more to go before she's ready to cut loose

fab work to the chassis is all done,drivetrain is all mounted, new brake/fuel lines, tub is mounted in place, just need money for a new clutch, before I mount the engine and front clip assembly. oh and some new sheet metal to build the new doghouse or tranny tunnel, whatever. Damnit, I hate minumum wage!

[leadfoot]

Well my truck performed well at the PJ party.The extended wheelbase seems to help and the gear reduction is awsome. The gear selection is wild. Power steering is such a joy to have :D . Everything was fine untill I snaped the joint on my A-arm at the rear diff. I was climbing a hill when that happened. The diff. then rotated upwards braking the driveshaft u-joint, and snaping off the shocks. The diff was pointing straight up and was jamed against the frame crossmember. John had to drag me the rest of the way down the hill to level ground so I could fix the truck. (good thing Pete had a spare tie rod) Going to replace the tie rod with a lower ball joint. Should hold up better I hope.

[szabotage]

yesterday my truck made its maiden voyage with its new setup. still a few bugs to work out but mechanically the dual transfer cases work excellent. all I need now is to relocate the fuel filler neck due to rubbage with the tires under flex and finish the rollcage, I ran out of argon halfway.

anyone know what my final drive ratio is? I worked it out to a possible 160:1 ratio but I may be wrong. I have the sidekick tranny/t'case and an 88.5 sammi t'case, 5.13's, and 33's

[billj]

How far back does this setup move the Sami t-case??? With the OTT kit and some others I've seen, the Sami t-case remains in the stock location. However, these have made a new shorter cover for the output of the Kick t-case and have shortened the output shaft......

Keeping the factory cover and shft length of the the Kick case would be easier and cleaner, but it would seem that the Sami case would have to be moved a lot to the rear.........

TIA,

[szabotage]

I think mine was moved back 8 inches from it's stock location, I was able to use a front driveshaft in the rear without modification but then again I'm using cj leafs in the rear and extends the rear axle out about another 3-4 inches back.my total wheel base is 100" front to back

[billj]

Thanks. That's what I figured, around 8 inches. That's too much for me, I've streatched my rig only a little bit and am using a centered diff. If I go any longer with the drivetrain, I'll have rear driveshaft problems.........

I guess I'll have to go the other route.......

Thanks!! :beer:

[Nemesis_y2k]

Is this streetable at all? I would like to do it because it seems it would offer me more streetability(and its cheaper) than doing gears, where I'll have a reduced ration ALL the time...

As long as I get my shafts rebalanced I should be ok right?

[szabotage]

yup its should be streetable as long as you get the driveshaft(s) and intermediate shaft balanced. I did mine by feel and came out lucky I guess, no vibrations at all speeds and gears.

mike

[Nemesis_y2k]

Kool, get on msn so we can finish that checklist and you can tell me why to wait on my lift...??? :)

[MUDSLUT]

setup works great, i have 36's on my sidekick and never run out of power.

[MuddMachine]

DONE !

You all know I'm "King of the Back Burner" but here ya go.......


:D

[Hoppin' Along]

Damn!!! Thats a nice job. As usual.

[KAC]

DONE !

You all know I'm "King of the Back Burner" but here ya go.......


:D

SHOW OFF ....I like Miss November

[Fullload]

DONE !

:D


Not yet. still not in the truck. :thefinger Nice work. you will have a happy LWB :thefinger

[MLC]

mine don't look that fancy but it does the job ...u'r gona like it :D

[MuddMachine]

Not yet. still not in the truck. :thefinger Nice work.

Ya had to spoil it... :thefinger

Thanx for the compliments guys... 'it's a sickness' :D

Oh, sorry bout miss november, december's up now that it was brought to my attention

:thefinger

[Superzuk]

good job... looks sweet

[Flanders]

Well that means you need to put one more pic on here. :rock:

[MuddMachine]

Well that means you need to put one more pic on here. :rock:

Thats right, Miss December :D

[Racerx70]

Anybody thought about using a rubber drive flange like on the landRovers for the connector between the kick t-case and the sammi? Then the alignment could be a little off and not have bearing or vibration issues.

http://www.roverunited.com/tech/land-rover-rotoflex/rotoflex-fix1.jpg

[szabotage]

that's a scary thought that landrovers use rubber flanges on their driveshafts, that must explain why they suck! :thefinger but seriously I'm surprised that rubber flanges actually hold up for them rovers, they must be using flubber!

[Canadian_zuk]

Some Volvos use the same setup. I've seen a few guys runnin dual Volvo trannies and one t-case. Tonnes more gear options, plus double reverse gives you a really stupid low forward crawl. These Volvo trannies they use are really short too. Works out to about the same space used as a dual case setup. If you put the second tranny in 4th (1:1) you end up with factory gearing back. They don't even touch their diff gears.

[someguy]

Anyone seen any more on the Volvo option, all I've seen is the Norwegian? guys. I have a LWB and would like to do something a little different, the two trans option seems interesting. Could it be done with Suz equipment? This site is getting better by the month, great to see the Cdn tech getting better. I would love to have a homegrown tech equivilant to P4X4 and I think you're getting close. I will try and contribute when I get the time to tear down my ride and make some changes (working full time, full time school and 18mo old daughter sucking up 20 hours a day for the next two months, insert sleepy smiley). I am doing a ton of reading in my "spare" time for my needs (4 link and gears) and this thread has anwered a few q's.
KEEP UP THE GREAT EFFORTS!!! :urock:
Had to add that VW used the rubber/viscious coupling on the Syncro and it seems to hold up well. I beat on a 86 Syncro Westy for four years (that one blew more than a few full-size minds) and the coupling held up well. Expensive to replace and it made some weird sounds when there was shock to the driveline but I never had to replace one....

[TheSarg]

I've heard of somebody around tryin a dual toy tranny setup, if it werks im sure he'll let us know ;)