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Lower Transfer Case Gears

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Y2GREY View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 19 July 2020 at 7:45pm
I'll scan it all in when I'm back in my office. I also have some email exchanges with Jack concerning tooth counts. He was interested in buying the case back and wanted to make sure it was a 4:86 which we confirmed it is.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 20 July 2020 at 9:53pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 20 July 2020 at 10:18pm
Here is an interior view of the 4.86 case. The take a close look at the intermediate gear and tell me what you see...  34/18

Edited by Y2GREY - 20 July 2020 at 11:38pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote rocnroll Quote  Post ReplyReply Direct Link To This Post Posted: 20 July 2020 at 11:08pm
Originally posted by Bob W Bob W wrote:

Originally posted by dasvis dasvis wrote:

 Is that a Lincoln or Hobart welding table?


It works with both.


.... ..... That's a 2APage Classic right there.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 20 July 2020 at 11:26pm
Originally posted by jpet jpet wrote:

I assume that the 4.10 set is actually 4.07
(49/19)8DP*(33/18)6DP

Since the 4.86 set uses the same 19 tooth input gear, it would have to be (49/19)8DP*34/18)..... but he has to use a special cutter because a 34/18 gear set would have like a 6.0665 DP which is non standard.

I am going waaaaayyyyy out on a limb here.......

I think Jacks gear ratios are.........
(49/19)*(31/20)=3.99
(49/19)*(33/18)=4.73

These ratios use two different stock Dana sliding gears. No special cutters.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 21 July 2020 at 12:45am
Originally posted by Y2GREY Y2GREY wrote:

....The take a close look at the intermediate gear and tell me what you see... 
34/18
Are you asking us or telling us?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote thesnoops Quote  Post ReplyReply Direct Link To This Post Posted: 21 July 2020 at 2:22am
Newbie question, but what’s the purpose in making the larger gear? Very impressive work. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jpet Quote  Post ReplyReply Direct Link To This Post Posted: 21 July 2020 at 3:06am
Originally posted by thesnoops thesnoops wrote:

Newbie question, but what’s the purpose in making the larger gear? Very impressive work. 
to get a loser crawl ratio and to give you wider divisions between gear selections, I.e six gears that do not overlap.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote thesnoops Quote  Post ReplyReply Direct Link To This Post Posted: 21 July 2020 at 3:16am
Thank you
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 25 July 2020 at 2:04pm
ROCKEATER_2020-07-25_13-52-29.pdf

Sorry for the delay on this I was having trouble getting the files to load.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Jw60 Quote  Post ReplyReply Direct Link To This Post Posted: 26 July 2020 at 10:50pm
On the rockeater case it looks like the top Transmission mounting hole is sleeved and the fastener would need to be longer. 

For those looking for the planetary underdrive Here is the link I had saved.

Now my question is how feasible would a doubler housing be between the Transmission and d18, put a rockeater d20 drive, intermediate, and rear slider in a case roughly 6 inches long? This would be more for a t-90c and not a 4 speed due to driveline length but I'm thinking it is possible and likely easier than the gears themselves.


Edited by Jw60 - 26 July 2020 at 10:52pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 27 July 2020 at 11:53am
[QUOTE=Jw60]On the rockeater case it looks like the top Transmission mounting hole is sleeved and the fastener would need to be longer. 

There is no sleeve. It appears that way due to the way it was palletized. It was just a long bolt with a large nut used as a spacer. The bolts were there to hold the cardboard cover in place.
 That is the Kluge link I had.



Edited by Y2GREY - 01 Aug. 2020 at 1:16pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote duffer Quote  Post ReplyReply Direct Link To This Post Posted: 27 July 2020 at 6:02pm
Looking at Y2GREY's photos it appears Jack's intermediate shaft installs from the front?  Do you have a photo of the front?  I barely have clearance for AA's nut and washer on the front of my D18 with an AA  transmission adapter.  I had to machine a new washer.

I am also a little concerned about the strength of the 5.18:1 gear design as my bucket list sbc build in front of the D18 will be putting out well in excess of 500 ft-lbs, hitting that mark at about 1500 rpm.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 30 July 2020 at 1:32am
Slowly making progress. Ordered some heavy duty detent springs and cut a chunk of 1" steel to make a cover for the top of the transfer case....





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Post Options Post Options   Thanks (0) Thanks(0)   Quote OnlyOneDR Quote  Post ReplyReply Direct Link To This Post Posted: 30 July 2020 at 6:30pm
Bob, I saw the hole you cut and need to mention that smoothing out any sharp edges and making clean radii in the corners are important.  I have not cut a case but I have cut and shaved differential housings.  You need to eliminate stress risers that could crack it during preheat/welding or later from cooling stresses.  I would also grind a chamfer on the edges of the block everywhere you will be welding it to the case as well as taking a flap disc to the mounting surface (not just a wire wheel) to get it as flat as possible.  If you have a welding blanket wrap it up immediately after welding so it can cool down slower (do it in a shop without the doors open or a fan running either).  For preheat that is such a large item it would be great to bake it in an oven as high as it will go.  I disagree with the instructions on not preheating the block; it is much better to have everything uniform in temperature as a block of that thickness (even after being hollowed out) will have similar expansion characteristics as the case.  I use ER70 wire with shielding gas, not arc w/rod, and have great results.   For a differential housing you need to weld inside as well but I do not see the need here.  I also would not hand-drill the transmission bolt hole, either have it aligned and machined or mark/drill it slightly larger on a drill press before welding and use a thick washer under that bolt head when assembling.  This will ensure that the bolt axis will line up.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 30 July 2020 at 11:52pm
Thanks for the recommendations!!!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Bob W Quote  Post ReplyReply Direct Link To This Post Posted: 01 Aug. 2020 at 12:43pm
Originally posted by Bob W Bob W wrote:

I am going waaaaayyyyy out on a limb here.......

I think Jacks gear ratios are.........
(49/19)*(31/20)=3.99
(49/19)*(33/18)=4.73

These ratios use two different stock Dana sliding gears. No special cutters.

I finally got around to actually counting some teeth. I pulled the PTO cover off of X98's transfer case and found the drive gear was 19 tooth, as expected. The intermediate gear has 50 and 20 teeth. So here are my new calculations, still using stock Dana sliding gears.....

(50/19)*(31/20)=4.07
(50/19)*(18/33)=4.82
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Y2GREY Quote  Post ReplyReply Direct Link To This Post Posted: 01 Aug. 2020 at 1:21pm
Finally got everything to upload...sorry for the delay



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