Best 3 speed transfer case?

[cruiseroutfit]

Cool...

 

[65swb45]

I am not trying to be argumentative here, but I just can't see how that will really help. The case crack doesn't start next to the gear, so trying to 'reinforce' the shaft or 'stabilize' that part of the case isn't going to change the main forces at work.

The crack starts at the top and comes down TOWARDS the idler. Conversely. the pressure of the idler would be strongest at the shaft, and would have to radiate out from there. The point at which the crack is starting is in a much thicker part of the casting than what the idler shaft sits in as well. Therefore, I do not see idler torque as a culprit for this particular problem.

What has always made sense to me is that the torque of the output shaft of the transfer case trying to turn the driveshaft puts a bind on the transfer case housing. The imput section of the housing is secured to the back of the transmission. Therefore, the fulcrum point becomes the first part of the transfer case that extends beyond the 'anchor' zone behind the transmission. That would be the top cover opening of the transfer case.

Anyone who has done a spring over without a trac bar can attest to the twisting force the driveshaft puts on the rear end, eventually bending the front half of the leaf springs and turning the nose of the pinion up towards the bed. This same force at the top of EVERY transfer case is working against the case.

Finally, if you have ever had the chance to order an brand new case [just the housing] from Toyota, you can look inside it and see that at the top inside corner, above the idler, there is a FLAW IN THE CASTING that predisposes it to cracking!

 

[PabloCruise]

The whine comes from the incorrect interface of the gears to one another, a distance that is set fairly precisely at the factory and has changed over time because of wear. Same way ring and pinions develop a whine when they are run with a loose pinion bearing; that noise will never go away either.

When the gears are allowed to move closer together because of sloppy or worn bearings and shafts, the extra friction and resulting heat start to polish and reshape the face of the gears. The more polish, the more whine. Changing bearings and shafts does not change the polish of the gears.

I am now sad after reading this. I was looking forward to a nice quiet case in my '78...

 

[PabloCruise]

Finally, if you have ever had the chance to order an brand new case [just the housing] from Toyota, you can look inside it and see that at the top inside corner, above the idler, there is a FLAW IN THE CASTING that predisposes it to cracking!

Does anyone have a pic of this?

It is fun reading and remembering Andrew by reading this thread.