Split-Case re-gearing, rebuilding and machine work

[orangefj45]

Yes there’s a spacer that goes between the two idler shaft bearings.

Georg @ Valley Hybrids, Cruiser Brothers & Long Range America

 

[Beerfix]

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!

 

[F226continental]

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

 

[cruiserpilot]

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.

 

[cruisermatt]

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.

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:

Cruiser Outfitters

 

[cruiserpilot]

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:

Cruiser Outfitters

Didn’t realize the tooth count was idler shaft dependant. Thx

 

[cruiserpilot]

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.

 

[Beerfix]

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.

 

[Advent]

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

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?

 

[orangefj45]

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?

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

 

[SteveH]

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?

 

[orangefj45]

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?

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

 

[cruisermatt]

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?

I think the Mark’s gears are 8% overdrive

 

[orangefj45]

I think the Mark’s gears are 8% overdrive

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.

 

[HemiAlex]

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.

 

[orangefj45]

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.

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

 

[Lead Head]

Does anyone have a video of what these Marks gears sound like? I'm very curious now.

 

[orangefj45]

Does anyone have a video of what these Marks gears sound like? I'm very curious now.

Videos never convey sound properly……

 

[Beerfix]

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

 

[orangefj45]

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

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
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