Split-Case re-gearing, rebuilding and machine work

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Yep yep, this little SOB here, was only a few bucks, and less than a day away at my local dealer. Of course my first thought was that I lost something out of the shaft kit, but turns out that it's not included. This is required when using the 34mm case, and the 38mm step shaft. Thanks @orangefj45 for the info, and a quick call back!

1626226980522788344153587552772.webp
 
George, what does the gear set , bearings, etc cost for the 4:1/under drive?

Any reason I can’t clearance my case on a Bridgeport with boring head?

I’ve got the big shaft 🤭
 
So there must be some kind of ratio change if a person uses a 34T McNamara gear swap as opposed to a 32T gear. Why were they later changed to the 32T? What is the difference? I can do math, but to be honest I don’t know how to arrive at an answer cause I don’t know all the other tooth counts, etc. I am curious about this.
 
cruiserpilot said:
So there must be some kind of ratio change if a person uses a 34T McNamara gear swap as opposed to a 32T gear. Why were they later changed to the 32T? What is the difference? I can do math, but to be honest I don’t know how to arrive at an answer cause I don’t know all the other tooth counts, etc. I am curious about this.
Click to expand...
The idler gears and hi/low gears tooth counts all change with the 34/38mm change. That’s why you can’t just mix/match gears from random t-cases.
34mm idler case input gear: 34 tooth
38mm idler case input gear:32 tooth

gear tooth counts:
 
cruisermatt said:
The idler gears and hi/low gears tooth counts all change with the 34/38mm change. That’s why you can’t just mix/match gears from random t-cases.
34mm idler case input gear: 34 tooth
38mm idler case input gear:32 tooth

gear tooth counts:
Click to expand...
Didn’t realize the tooth count was idler shaft dependant. Thx
 
Having run Marks Australia 3:1 gears for the last 5 yrs I’m happy to announce I’ve completed a swap to Sumo 3:1, both 1:1 high range. For five years I’ve suffered from horrible gear whine with the Marks gears.
The Sumo gears have NO associated extra gear noise that I can hear. I drive both this truck and a stock BJ74. Happiness reigns!
Thanks for all the research and development of these gears. Right, tight and ready to hit the Yukon as soon as I’m off work.
 
Things are coming together. Amazing, given the other projects I have concurrent, and the fact that I have only an hour or so every couple of days to devote to the 'Cruiser.

gears.webp


cased.webp
 
orangefj45 said:
Important note!!!!
With the low gear sets, you have to run the factory drain plug on the transfer case. You cannot run the 10 mm Allen style plug because it will hit the gear.
You also have to run the transfer case main shaft from a manually shifted case, not the vacuum shifted case.
Attached is a picture showing bull shaft. The vacuum shaft with thr straight splines at the top, the mechanically shift shaft with the “pinched” splines at the bottom.

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America

View attachment 2660323

View attachment 2660324
Click to expand...
Does this mean the 3:1 gears cannot be used with vacuum shifting? I really like it, personally.

Also, are these shafts still available or does one need to be found?
 
Advent said:
Does this mean the 3:1 gears cannot be used with vacuum shifting? I really like it, personally.

Also, are these shafts still available or does one need to be found?
Click to expand...
You CAN run the 3:1 gears with the vacuum case ( has to be machined ) but you HAVE TO change the Tcase output shaft to the mechanically shifted version with the “pinched splines”. This will allow you to retain the vacuum shifter and you will not have any issues with the case popping out of low range.
We have the gear sets, shafts and rebuild kits in stock.
Happy to help.
Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
 
The first set keeps high range at a 1:1 ( direct drive ) ratio and lowers the low range to a 3.1:1, from the factory 2.28:1.
The other set they offer changes the high range to a 10% under-drive and offers a 4:1 low range ratio.

Since you specialize in the impossible, how about an 10% overdrive in high range to push the H55 5th gear ratio a big higher (lower numerically)? That way, I would not need to run 33s on my FJ62 or install 3.73s. Would this even be physically possible inside a split case?
 
SteveH said:
The first set keeps high range at a 1:1 ( direct drive ) ratio and lowers the low range to a 3.1:1, from the factory 2.28:1.
The other set they offer changes the high range to a 10% under-drive and offers a 4:1 low range ratio.

Since you specialize in the impossible, how about an 10% overdrive in high range to push the H55 5th gear ratio a big higher (lower numerically)? That way, I would not need to run 33s on my FJ62 or install 3.73s. Would this even be physically possible inside a split case?
Click to expand...

Yes absolutely. Fairly straight forward modification but would require you to replace the idler gear in the Tcase as well. We have all those items in stock.
Here to help
Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
Shop 209-475-8808
Sales@valleyhybrids.com
 
SteveH said:
The first set keeps high range at a 1:1 ( direct drive ) ratio and lowers the low range to a 3.1:1, from the factory 2.28:1.
The other set they offer changes the high range to a 10% under-drive and offers a 4:1 low range ratio.

Since you specialize in the impossible, how about an 10% overdrive in high range to push the H55 5th gear ratio a big higher (lower numerically)? That way, I would not need to run 33s on my FJ62 or install 3.73s. Would this even be physically possible inside a split case?
Click to expand...

I think the Mark’s gears are 8% overdrive
 
cruisermatt said:
I think the Mark’s gears are 8% overdrive
Click to expand...
The Sumo gears are 10% …… and you won’t need to wear ear muffs when driving your cruiser, which you would have to do with the Marks gears.

The end.
 
I was just wondering about this.

Can you hear the 4:1 gears with the under drive over a set of mud terrains at cruise? Asking for an Alex.
 
HemiAlex said:
I was just wondering about this.

Can you hear the 4:1 gears with the under drive over a set of mud terrains at cruise? Asking for an Alex.
Click to expand...
Any aftermarket Tcase gear set typically makes noise. That holds true for the 4:1 gear set but it’s minimal and the tire noise will “drown it out”.

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
 
So after taking my sweet time, (Georg got my case halves and parts back to me in early May) and an extremely busy work schedule this summer, I finally got a trip in with the new 4:1 gears. I have to say, this has to be absolutely the most meaningful upgrade I've done on this project so far. The V8 is a close second... The difference is night and day, even on mild trails. It make things so much easier, pleasurable, and confident in the ability of the vehicle. I cant speak much on additional noise, since I have a noisy rig to begin with. You do hear some gear noise on overrun/decel in low range, but I kinda like it. It sounds like a gearbox should. On the freeway at 75, windows down, the Ranger Torque splitter in overdrive and tunes turned up, well, you get it. Anyone on the fence about this, DO IT, do it now, you wont regret it. Thanks again @orangefj45
 
Beerfix said:
So after taking my sweet time, (Georg got my case halves and parts back to me in early May) and an extremely busy work schedule this summer, I finally got a trip in with the new 4:1 gears. I have to say, this has to be absolutely the most meaningful upgrade I've done on this project so far. The V8 is a close second... The difference is night and day, even on mild trails. It make things so much easier, pleasurable, and confident in the ability of the vehicle. I cant speak much on additional noise, since I have a noisy rig to begin with. You do hear some gear noise on overrun/decel in low range, but I kinda like it. It sounds like a gearbox should. On the freeway at 75, windows down, the Ranger Torque splitter in overdrive and tunes turned up, well, you get it. Anyone on the fence about this, DO IT, do it now, you wont regret it. Thanks again @orangefj45
Click to expand...


Love it when a plan comes together!

Stoked to hear that the results are everything you wanted the combo to be.

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America
Shop 209-475-8808
Svh
 
You must log in or register to reply here.

Share this page

Back
Top Bottom