Marks4wd Cruiser Crawler Install

[Wrench]

Well I'm the lucky or unlucky guy depending on how you look at it who bought Action Jackson's crawler box. This was a bigger project than I anticipated. The box doesn't fit as advertised. There is some grinding that needs to be done to make it fit US transfer cases. It's a shame because the amount of money the crawler cost it should be a simple bolt on. I can understand gas tank and floor mods those where easy but it is the other stuff that is a real pain.
I wanted to install it without a body lift and not remove the transfer case from the vehicle. I did the whole install with little to no help on a dirt driveway. Which really sucked. It took me five days to get it installed and running.
First I modified the gas tank. I got free labor from my Landlord. He was gracious enough to weld it for me as I was a little nervous doing it myself. He said there was nothing to worry about. "Just hook a car exhaust to it" Yeah ok....I just stood far away. Surprisingly nothing went BOOM!
Marking where to cut.

It's been cut...no going back now.

Cut piece

A look inside

Getting ready to weld

My landlord welding it up. No boom so it's safe. lol

Completed tank

Installed in the vehicle

So after the gas tank was done I went on to do the transfer case.
So after taking the rear extension off and splitting the case this is what you see. Input shaft removed.

Instructions tell you to grind half of the two small ribs near the splined shaft for clearance.

Interface housing needed to be modified to clear oil pump relief valve. So did the box.

Here it is installed on transfer case. With the new input shaft and gears installed.

On to the floor mods.
Here's where I had to cut and raise the floor.

Ouch! First cut no going back now. He He

Floor all cut and crawler raised into position. It comes approx. 4" into the interior. So even with a 2" bodylift I would still have to cut.

Completed floor.

Needed to cut a notch in the body crossmember to fit air valve.

Here's what it looks like mounted. Gas tank not installed.

People say this is the greatest mod you can do to an 80. I have to agree. This thing is bad ass! I love it! It works so well. I have so much more control now. It is so low I can get out and walk with it. It is so relentless on the rocks. You really can't slow it down. Although it was a pain in the rear to install it was well worth it! I love this thing!

 

[FJ809496TLC]

Crawler sucks! I wonder what would be the limit of degree climb if any?

 

[Cruiserdrew]

Dang-do the booger welds on the fuel tank hold gas?

It looks scary, but I wish I had one. Nice going..

 

[Doc]

Maybe I don't understand how this thing works, but isn't there supposed to be an additional shift lever to put it in 'super low'? Or is the factory low range eliminated with this install?

 

[Wrench]

Dang-do the booger welds on the fuel tank hold gas?

It looks scary, but I wish I had one. Nice going..

Surprisingly it does hold gas. What do you want for free labor?

 

[Dusty]

Brova sir
3 links, 37's, bilsteins, longfields, or whatever

none of these frequently revisited topics comes close to making the 80 a true rockcrawler when compared to crawler gears

until easier and cheaper tcase gearing option becomes available the 80 will never see its true potential

(stepping off soap box)

 

[Nay]

Brova sir
3 links, 37's, bilsteins, longfields, or whatever

none of these frequently revisited topics comes close to making the 80 a true rockcrawler when compared to crawler gears

until easier and cheaper tcase gearing option becomes available the 80 will never see its true potential

(stepping off soap box)

Dusty's right. The single biggest gap in the entire 80 market is an easier and less expensive low range reduction. The 80 doesn't need a bunch of suspension tweaks, it needs control of the weight and size in the big rocks. He who solves that problem stands to make many a sale.

I bit the bullet and am putting in 5.29's, and now just need the low range...

 

[Kalawang]

What did you do to discourage rust on your welded gas tank ? I've seen welded tanks rust through within 2 years.


Kalawang

 

[-Spike-]

Maybe I don't understand how this thing works, but isn't there supposed to be an additional shift lever to put it in 'super low'? Or is the factory low range eliminated with this install?

The 3:1 crawler box reduction is air-actuated.

And I'm super-envious.

-Spike

 

[GXO]

very cool. I will very much want to do this on the buggy build when I cross that bridge...in several years

 

[TiredIronGRB]

Dusty's right. The single biggest gap in the entire 80 market is an easier and less expensive low range reduction. The 80 doesn't need a bunch of suspension tweaks, it needs control of the weight and size in the big rocks. He who solves that problem stands to make many a sale.

I bit the bullet and am putting in 5.29's, and now just need the low range...

Well said... I'm thinking about going to the 7.19 gears in my Volvo axles (currently 5.99). However when and if a crawler box comes out that bolts in with little modification and is non-air operated I will purchase one if I have to finance it.

 

[Waggoner5]

I see that you have the latest gen of crawl box. Thats good. I just put the update kit in mine to fix all of the issues with this box. Mine and Christos boxes both jump out of gear and overheat when running down the road in 1:1, not crawl. The fix is a new gear system which slows down the idler gear in 1:1. I have not driven mine yet, but plan to tomorrow.

An easy fix to not having to grind the adapter or housing is to use the short rear output or pre VC TCase output. You will use the center section of the early case and the early rear output case. This will give lots of clearance but a lengthened rear shaft will be needed.

Good luck on the rest of the install and see you on the trail.
Gary

 

[Waggoner5]

A replacement case is coming, but "they" are taking there time on the building of the first one.

 

[Wrench]

What did you do to discourage rust on your welded gas tank ? I've seen welded tanks rust through within 2 years.


Kalawang

Well the inside I coated with tank sealer. And the outside I just painted with rustoleum. I hope it won't rust out that fast.

 

[Wrench]

I see that you have the latest gen of crawl box. Thats good. I just put the update kit in mine to fix all of the issues with this box. Mine and Christos boxes both jump out of gear and overheat when running down the road in 1:1, not crawl. The fix is a new gear system which slows down the idler gear in 1:1. I have not driven mine yet, but plan to tomorrow.

An easy fix to not having to grind the adapter or housing is to use the short rear output or pre VC TCase output. You will use the center section of the early case and the early rear output case. This will give lots of clearance but a lengthened rear shaft will be needed.

Good luck on the rest of the install and see you on the trail.
Gary

That's cool. I got the upgrade kit in mine. I never heard the old one but this one makes a lot of gear noise.

 

[Junk]

The way you drive you don't need a crawl box. LOL gunit2runit.

 

[landtank]

so with the cut down tank and lower gearing what's your range, a mile and a half?

 

[concretejungle]

so with the cut down tank and lower gearing what's your range, a mile and a half?

bwahahahaha

 

[Wrench]

so with the cut down tank and lower gearing what's your range, a mile and a half?

Ok very funny lol...
On the street it's runs in 1:1 so little change and the gas tank I lost like 2 litres. Big deal. People whine about that but it really is not a problem I have not noticed a difference. Mileage doesn't seem that bad.
On the trail im not worried about it..

 

[Wrench]

The way you drive you definitely need a crawl box. LOL gunit2runit.

Fixed it for ya