Intermediate Reduction box

[JesseA]

Over the last few weeks ive been contemplating lower gearing. In the axles and the transfercase.

the other night while i was drifing off to sleep i thought about a planetary set I aquired for a science project some years ago. Its pretty big, The guy said it was an overdrive unit on a GM transmission, but its a solid 5 inches across the ring, and has a 3:1-ish reduction. I had the thought to capture the planetary set with some bronze bushings and steel plate, fill it with oil and weld a set of yokes to the shafts. Have an arm on the ring to secure it and cause a transfer of power. Id be putting this in place of the Jackshaft.

But i had some questions- would the suzuki samurai case be able to withstand that amount of torque? (about 3x normal) How will the arms and the rubber mounts survive?

I plan on running small tires 31-32s, I may keep the stock gears for the time being, but have plans to switch to 5.38 gears soon.

thoughts?
Thanks
Jesse

[MLC]

great idea ....i know the arms won't take it but if u beef them up they should be fine and maybe a t case bucket would be a good idea ..keeps the tcase from splitting under load .....thats my .02 ;)

[Depot]

do a search for t-case stuff... u will start by ripping mounts, then bending the arms, followed by splitting the case open all depending on how much power ur putting to it and how hard u drive it.

gl

D

[MLC]

if anybody knows about breaking stuff Depot does ...lol :D

[JesseA]

I ripped one mount already.

Im not sure, but i may have bent the pass side arm. can i just re-enforce the mount and link them together? that is kinda how the Buckets work correct?

[Depot]

do a search! I've posted a lot about this issue.

gl

D

[MUDSLUT]

i have dual t-cases and i was constantly breaking the 2nd sammy t-cases in half and snapping toyota pinions like butter, i added a plate that is bolted thru the bolts that hold the tranfer case together, covered a 4 bolt span on the lower right hand side, and used 2 stock sammy rubber bushings underneath to a custom arm. finally have no more movement and no breakage. If you're going with the gear reducer you have planned, i would suggest keeping the stock diff gears, much cheaper and more plentiful.

[KAC]

http://www.zookpower.ca/forums/showthread.php?t=594&page=2&pp=15&highlight=t-case+mounts


Good t-case mounts

[Fullload]

I may have to go with the "depot style" mounts now as well. That 16 valve even with the mighty kong is just chewing them up to shreds. so far just the short arm so i'll change that to bombproof first and see what happens.

[Depot]

u already have the mighty kong so when u bombproof ur mounts, it'll start to rip the brace off the frame..... member my come along at suzican.. thats why. Someday i'll buy my own digicam and snap some hsots of how I solved that problem.... hey, its my b-day next week.. anyone wanna buy me one? :D

D

[JesseA]

i have dual t-cases and i was constantly breaking the 2nd sammy t-cases in half and snapping toyota pinions like butter, i added a plate that is bolted thru the bolts that hold the tranfer case together, covered a 4 bolt span on the lower right hand side, and used 2 stock sammy rubber bushings underneath to a custom arm. finally have no more movement and no breakage. If you're going with the gear reducer you have planned, i would suggest keeping the stock diff gears, much cheaper and more plentiful.

these werent 10 spline toyota FJ40 pinions were they? Ive seen three of them fail so far.

I had planned on building a Bucket that usues bolts on both the front and the rear of the transfercase at the outputs to retain it as well as the ones along the spine on the bottom. Kinda like a tcase girdle if you will.

I found this one on PBB The other day; http://www.pirate4x4.com/forum/showthread.php?t=297269

Mine will prolly be somwhere between Depots and this one. (hopefully)