Lower Transfer Case Gears |
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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Posted: 13 July 2020 at 11:09pm |
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Hi all,
I feel like this project is far enough along that It’s worth posting on. The is a project that Bob W and I are working on along with some contributions from Joe Friday, Metcalf, and pts211 This is a 19 tooth pinion to 49 tooth intermediate gear. The Helical teeth are 8DP 20 deg pressure angle and 20 deg helix like the originals The low range spur gear is 21 tooth 7DP which is the same as a stock 1-1/8” shaft Dana 18 case. This way we can use the original 39 tooth slide gear which is one less gear to make. The low range is 4.79:1. Yes the gears come through the case: First to be able to see some geometry and the case cutout, both Metcalf and pts211 3D printed me some gears: Now to cut the case: This is a d20 case. The gear is 6.4” diameter and the teeth are about flush with the outside of the case. Obviously, the cutout will have to be covered with a plate but there is plenty of clearance for a bolt. Since there is more clearance than I expected, I think I will experiment with a 3mm tooth gear set instead of 8 DP. A 3mm 53 tooth intermediate gear would be 6.5” in diameter. If I go with a 3mm tooth, I can do a 19/53 tooth helical gear combo which will make low range 5.18:1 In series with a T90-C and 5.38 pumpkins, the FDR would be 93:1 93:1 52:1 (Stan gear) 28:1 18:1 10:1 5.38:1 .... those are real good splits IMO. ... more ... Edited by jpet - 13 July 2020 at 11:20pm |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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.... anywho, our shop is not setup to cut gears. I’ve sent these prints out to several gear shops. Either they won’t touch it because it’s automotive, or they want a minimum order of like 100 sets. Eventually, I found a guy in Indianapolis who will cut the teeth for me if I do all the rest of the work. We are not setup to do internal splines either and I hate to spend a bunch of money farming them out when I’m still in R&D so I made a bushing that has a 60 deg key so that I can index it to make splines. :
... the splines are 11/32” wide but all we have is a 5/16” broach so I made the slot in the bushing wider so that I can put shims on the sides and run the broach thru twice: These splines are flat on the outside edge but They are still tangent with the 1-3/8” shaft diameter so I’m satisfied that they are good enough for R&D. That was the one thing I wasn’t sure how to do. I also have to make the dog clutch for the slide gear. I plan to interpolate that in the CNC mill. We don’t have a shaper so we shall see. That’s it for now. |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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Here is another possible concept of an original intermediate gear machined to use a 49 tooth ring gear:
Metals: I have not made hardened gears before. After lots of reading, I decided to get some 8620: What I had read was that after you cut the teeth, you have this metal carburized and then heat treat the teeth about .03 deep. After talking to the heat treat guy, he is telling me to go with 4140 which doesn’t need carburizing .... IDK. I sent him some original gears to test them for hardness and make a recommendation. More on that as I get info. |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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Lee MN
Member Joined: 13 Aug. 2008 Location: Harris, MN Status: Offline Points: 4955 |
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Very interesting! 👍🏽👍🏽👍🏽👍🏽
Lee |
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LEE
44 GPW-The Perfected Willys 49 2A “If you wait, you only get older” 67 M715 American Made Rolling History |
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jeepsterjim
Member Joined: 13 July 2011 Location: lincoln, ca Status: Offline Points: 1283 |
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WOW great stuff!
This would not work with a 29 tooth geared set up? nor a x-fer with a OD? glad to see you guys working on ways to lower the gears in the x-fer case.
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Jim
CJ-2A - 81299 |
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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Yes, it would work with 29 or 26 tooth setup because you are replacing those with the 19 tooth gear anyway. No overdrive though. The 19 tooth is just too small. |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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hotrod59
Member Joined: 28 Dec. 2017 Location: Boise, ID Status: Offline Points: 107 |
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Wow this is amazing! I will be following this. Great work guys!
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1948 Luzon red CJ2A No name yet
1952 CJ3A "SPUDZ" |
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otto
Member Joined: 26 Feb. 2012 Location: Orygun Status: Offline Points: 2267 |
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This is fascinating, very innovative method of creating the internal splines. I have been to the Warn facility where they were making parts and they had broaches that were about six feet tall and pushed them through all in one pass. Always wondered how splines were made; interesting process.
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47 CJ2A w/fuel injected boat engine
48 CJ2A 64 Ford Econoline Travelwagon If you can't get there in a Jeep, get a motorcycle! |
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Joe DeYoung
Member Sponsor Member x 2 Joined: 20 July 2005 Location: Madison WI Status: Offline Points: 3362 |
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I'm thinking you would get much less material growth and distortion after heat treat using 8620 carburized for a .030 case vs the 4140 hardened all the way through.
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Joe DeYoung
to many jeeps, parts, and accessories to list here, but apparently enough to keep me in trouble with my wife. |
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Metcalf
Member Sponsor Member Joined: 21 May 2009 Location: Durango, Co Status: Offline Points: 736 |
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Happy to help Jeff. Keep up the good work. |
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42 MB that had a one night stand with a much younger 69 CJ5 and a 50s GM truck.
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Joe Friday
Moderator Group Sponsor Member x 2 Joined: 26 Dec. 2010 Location: Jeep Central Status: Offline Points: 3655 |
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Jeff,
wetransfer was acting up when I tried to send you files. If you are missing any dimensions please let me know and I will email individual files.
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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Hi Keith,
I’m looking for the dimensions on the dog clutch and also what material the gears were made from. I talked to the gear guy today and he strongly recommends the 8620. He makes gears for competition tractor pulls so that’s good enough for me. |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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I’m also curious what the engineer called out for the spline width. The originals I’ve measured are about .345 wide. I assume they had to do the same heat treat compensation that I am.
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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Metcalf
Member Sponsor Member Joined: 21 May 2009 Location: Durango, Co Status: Offline Points: 736 |
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Has 9310 type material come up at all in discussions? Seems to be really common for high end gear manufacturing. The heat treat can tune the durability vs longevity over a broad range. |
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42 MB that had a one night stand with a much younger 69 CJ5 and a 50s GM truck.
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Bob W
Member Sponsor Member x 4 Joined: 08 Aug. 2005 Location: Monticello, NY Status: Offline Points: 1693 |
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The dog clutch is on the A-15044 or 809291 gear output shaft. Here are part numbers for all the gears in question for both 1-1/8" and 1-1/4" intermediate shaft gear sets. A-10469 or 809297 gear mainshaft (input)642189 or 809293 gear intermediate A-15044 or 809291 gear output shaft A-15045 or 809290 gear sliding |
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Joe Friday
Moderator Group Sponsor Member x 2 Joined: 26 Dec. 2010 Location: Jeep Central Status: Offline Points: 3655 |
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I texted you A-992
Was it 807892 you were looking for?
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174 |
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... another compelling reason to make them from that material along with the fact that I've already spent 600 bucks on material |
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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chasendeer
Member Joined: 24 Feb. 2012 Location: Napa,CA Status: Offline Points: 1088 |
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Jeff and all involved,
Thanks for taking on this project, in a much needed group of parts for this hobby. Jay
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