H2FAV into a 1992

[cdsmith2002]

I didn't find any thread where someone said that they actually did install a viscous type into an older non-viscous truck. My truck has 283K on it and has a thud in the drive line when >50MPH when coasting.

I ordered a used non-viscous type transfer case but the yard sent me a viscous type by mistake. I'm considering installing it. Besides needing a different rear drive shaft, are there any issues? I looks like it clears the gas tank and the exhaust. Other that adding a heat shield due to the exhaust routing, any other fitment issues?

 

[Alleycats]

I wonder if it's the same length at the rear output shaft?

 

[strictlyRUM]

Its not. The viscous is much longer. I have one of each on my floor right now.

 

[jonheld]

My truck has 283K on it and has a thud in the drive line when >50MPH when coasting.

You're trying to fix the "Land Cruiser clunk" with a different transfer case. All non-viscous center diff 80 Series do this to some degree. Mine has done it for the last 200K miles. Learn to love it.
There are ways of minimizing the "clunk", but it stems from the accumulated slop in the driveline, mostly from the front. You will find that if you lock the center diff while traveling straight, the clunk will magically vanish.

 

[cdsmith2002]

I had read some threads about the clunk but not many success stories.

The clunk/thud is very concerning. The diff's and U-Joints are OK. It's mentally fatiguing to drive on the highway, trying to manage/minimize the backlash during driveline coast. I want to address before a 3200 mile trip in August.

Was hoping to hear from someone that has done the swap before I begin. I'm also looking forward to tearing down the old case for inspection.

 

[cdsmith2002]

The truck sat from 3/2017 until now. Fired right up in 3 seconds. The truck has new 4.88 gear sets. Sadly ,it has the same ole road speed clonk/thud after going into drive-line coast and back to drive-line load.

Back in 2016, the viscous type transfer case didn't change anything. I disassembled the original transfer case and nothing was worn out. I have the factory manual. Backlash etc was OK.

I have two first GEN Ford Explorers (92 & 93). Those trucks disengage the torque converter lock up if you lift throttle, by design, to reduce harshness. The Cruiser does not do this, it stay locked. I didn't find any documentation on if this is normal or not.

I guess I'd like to drop the transmission and look at the input shaft splines. Some day......