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post #1 of (permalink) Old 02-21-2002, 12:49 PM
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Transfer case

I have been wondering what I can do to transfer case I already have to reduce the gears or out put. I know I can buy a gear reduction, but can I move gears or weld gears for the same or near same effect. Thanks

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post #2 of (permalink) Old 02-21-2002, 01:03 PM
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Re: Transfer case

Well, I guess since nobody is answering you, this is one I know the answer to: NOPE.


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post #3 of (permalink) Old 02-21-2002, 02:22 PM
 
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Re: Transfer case

Breeze makes a welded gear set for like $200.00, I don't know what else you would need to install them.


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post #4 of (permalink) Old 02-21-2002, 09:53 PM
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Re: Transfer case

Im with 1.3 on this one, no, you cant. You cant just move gears here and there and weld stuff. These things have to be made VERY precise, nothing a person can do at home.

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post #5 of (permalink) Old 02-21-2002, 10:41 PM
 
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Re: Transfer case

I think what you're thinking of is the early rock-lobster sets that used high range from a samurai case, and low range from an SJ case(I think thats the right way around) The way it was done was to cut the 2 intermediate gears, and weld the resulting 1/2s together - as stated, the tolerances are pretty darn critical - IF you're an A1 type welder, you can probably get away with it ( especially if its a trail only rig) otherwise, save yourself major headaches, and just buy a pre-made gearset!

FWIW - I've welded up a few driveshaft flanges to make custom divorced case conversions this way with good results, so it IS possible for a DIY'er.....but I wouldnt recommend trying it on expensive or hard to find parts.

chris

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post #6 of (permalink) Old 02-22-2002, 01:50 AM
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Re: Transfer case

Don't forget that beyond the precision machining and alignment tolerances within 10thousandths of an inch, you must fabricate and use a compression jig so the welded pieces cannot move. A TIG weld on the gears is also the proper way to do things.... NOT stick or MIG!

You can get quality manufactured and lifetime guaranteed 4.16 gear kits for as little as $399. Pretty darn cheap when compared to lower gears for any other 4x4 on the market.


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post #7 of (permalink) Old 02-22-2002, 10:13 AM
 
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Re: Transfer case

wow 10thousandths of an inch one shop that I work at milled wood to within .002 had to use it the same day or it would start to swell and not fit into the fixtures but I agree the T case gears would be difficult to make for most I have a very nice machine shop at my disposal and I still bought mine





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post #8 of (permalink) Old 02-22-2002, 02:48 PM
 
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Re: Transfer case

glen - I agree entirely thats its cheaper, easier ( and safer 8^D) for most people to buy a gearset - but 10 thou? are you talking runout, shaft misalignment or what? Put bluntly, the tolerance on the bearings inside the case isnt that close, so even if you DO machine to that tolerance, its wasted. I've built modifed transmission flanges, spliced t-case gearsets, and done live axle-to-ifs housing conversions using nothing more than (new) bearings, and a dial indiactor to set them up, and I've never had a problem with them : the precision welding required for a balanced assembly is considerably harder than the physical setup/tolerances.

so where does the 0.001 tolerance cone into play?

Chris

91 Niva 'Cossack', MB 240D, 4 speed auto, ~88:1 low, 30x9's, coil sprung, 830 RTI.
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post #9 of (permalink) Old 02-22-2002, 05:32 PM
 
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Re: Transfer case

The welded cluster gears on the market have about .004"-.007" runout. The tenthousandth (.0001") tolerances apply to making
new gears,not welding them together.
Here's the roblobster article. http://redgum.bendigo.latrobe.edu.au/~jeff/xfer2.htm

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