Mounting a 3 speed Tcase on a 4 speed tranny

[natvet]

This is how I mounted a 3 speed Tcase on a 4 speed tranny This doesnt mean I did it right. In fact please comment on any and all the mistakes I made or changes that should be made.
Coleman’s. site was the invaluable for instruction on this swap.
What I used/bought/traded for
Tcase input gear (pic 1 ) from Cruiser outfitters
Tcase bearing(pic 2) from cruiser outfitters
Tcase to tranny bolts and output shaft nut (pic 3 ) Longer bolts from 4 speed tranny. shorter bolts from 3 speed tranny cruiser parts.net
Spacers instead of PTO gear (pic4)
4 speed shifter linkage.. cruiser parts
4speed hi/low shifter mechanism (pic 6 ) from a 4speed case
2wheel to 4 wheel shift accuator ( pic 8 ) from a 4 speed case.
Here are the pics All the new /conversion stuff in on the left….old stuff on the right
1.tcase input gears
2.bearings
3bolts/nuts

 

[natvet]

Spacers

pic 4 spacers

 

[natvet]

Hi/low shifter difference

the angle of the hi/low shifter is different for a 4 speed to a 3 speed tcase. I swapped the 4 speed shifter into the 3 speed Tcase.

Shifter mechanism from the bottom to show difference in orientation(pic5)
4speed hi/low shifter (pic6)
3speed hi/low (pic7) with new orientation drawn on it

 

[natvet]

2 to 4 wheel drive

The 2 to 4 wheel drive shifter(accuator....sp) is also different. I put the entire accuator from the 4 speed on the 3 speed tcase. you could also change the whole nose cone

4speed 2to 4 wheel drive shifter
3 speed 2 to 4 wheel drive shifter
Accuator removed from nose cone

 

[natvet]

Shifter linkage

The entire shift linkage was also replaced pic 6 shows the 4 speed linkage to be used. For now it back to work I will post all the install pics later today.

 

[natvet]

Puttin it together

I remove old Tcase from tranny per FSM.
Install
Place new oil seal in front of tcase(no pic) place new gasket btwn tcase and tranny(cruiser outfitters)
Placed new tcase input gear in tcase and placed entire tcase on output shaft of tranny
Placed spacer(inplace of old PTO gear or spacer)
Bolt placement 3 long bolt on outside of Tcase, 2 bolts inside case see pics for size

 

[natvet]

bearing

Placed new bearing on tranny output shaft w some 90w oil. It is a tight fit. I used a brass drift to tap the bearing into place. I made the bottom of the bearing flush with the inside of the Tcase?? there was still some play btwn spacer and bearing inside the case???
Placed shorter spacer on outside of the bearing then washer and then nut.

 

[Coolerman]

So far so good! Excellent labeled pics of the shifter linkage.

 

[natvet]

4wd accuator

next I removed the long 4wd accuator(4WDA) from th 4 speed Tcase and placed it on the 3 speed Tcase After taking it apart and cleaning it
1. pic of 4WDA off nose cone
2. pics of accuator parts (took appart to clean) this is acually the 3 speed accuator forgot to take pics od 4 speed but they are the same inside Ball bearing and spring are under the front bolt
3. pic of second bolt in the accuator that when removed allowed removal and cleaning of the shaft and insides ........Others have said you could place the 4 speed accuator shaft in the 3 speed and it would work....... I did it for fun and it worked then I changed it back.

 

[natvet]

Shifter linkage

Last step I removed top cover of tcase and put the 4 speed high/low shifter in the top cover to create the correct angle for the hi/low shifting linkage

Pics of linkage from different angles. With labels

 

[natvet]

Thats all

That is about it. I am sure I forgot something please speak up if i did. Hope this helps someone else trying to do this.

I have more pics of the different steps if you would like to see specific things just ask

 

[natvet]

Thanks

So far so good! Excellent labeled pics of the shifter linkage.

Thanks alot Coolerman.