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post #1 of (permalink) Old 10-01-2003, 09:45 PM Thread Starter
 
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pictures & details of 2-low tcase mod

Hey all,

I recently installed the new calmini 6.5:1 DL gear set in my 87 transfer case. While it was apart, my buddy made the mods to the shift fork to enable the 2-low feature. The picture shows the stock shift fork rods. Notice that they both have the same length 'notch' cut in them.
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File Type: jpg 1196119-stock zuk tcase forks.JPG (29.6 KB, 290 views)
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post #2 of (permalink) Old 10-01-2003, 09:51 PM Thread Starter
 
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Re: pictures & details of 2-low tcase mod

This picture shows how the shift fork is modified. The front shift fork (the one with the collar), or the fork that selects 2WD and 4WD has the 'notch' extended by exactly 0.315 inches. The cut extends towards the back of the fork or towards the weld bead.

I have been told that this can be done by an angle grinder, but we had an end mill handy
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File Type: jpg 1196122-modified zuk tcase forks.JPG (32.8 KB, 273 views)
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post #3 of (permalink) Old 10-01-2003, 09:55 PM
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Re: pictures & details of 2-low tcase mod

i thought this could be done by removing a ball bearing somewhere? mind you this way seems so much easier to get it into 2low.
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post #4 of (permalink) Old 10-01-2003, 09:56 PM Thread Starter
 
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Re: pictures & details of 2-low tcase mod

This last picture is just a close-up.

Remember that you also have to remove the center ball bearing between the shift forks. The outer 2 ball bearings remain in place.

-Paul in Fort Collins, Colorado
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post #5 of (permalink) Old 10-01-2003, 10:22 PM
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Re: pictures & details of 2-low tcase mod

Correct on the ball removal. Regardless, either way requires the ball removal. The mod. that does not modify the fork requires a different alternate 2wd low pattern in addition to the normal pattern. Never seen/used the mod shift fork version, told it was easier to use.
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