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Old August 25th, 2011, 09:52 PM   #21
cerial
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Yea I totally dropped the idea of the transfer case on the axle. It would never fit in a 5 even if I raised the floor and relocated the tank.
Just one of my crazy ideas that I did not think through before rambling about it.

The 225 is a great engine. Believe me I was so impressed with the dauntless that I drove 4 hours a day after buying the jeep and bought a non running one that I was told had 25 k on it for $1000. This was back when I was going to make this into a restoration. This has gone way away from being a restoration to a all out custom. The crate 383 has been chosen out of saving time and cash over rebuilding the 225.
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Old August 25th, 2011, 10:23 PM   #22
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Originally Posted by ovrlnd View Post
this mod makes no sense.
While using a Dana 18 was not the best choice for the cj5 you need to remember that I planned on flipping the Dana 18 backward on a 5 ton Rockford axle to begin with on a larger project.

I still believe a transfer case flipped around could work as a low cost way to turn a 5 ton Rockford into a 2 speed rear end for those wanting to use the (0.4/1 to 0.7/1 depending on the case)higher ratio to reduce rpm or whatever other reason a higher ratio could be used for.
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Old August 26th, 2011, 02:37 PM   #23
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Originally Posted by cerial View Post
While using a Dana 18 was not the best choice for the cj5 you need to remember that I planned on flipping the Dana 18 backward on a 5 ton Rockford axle to begin with on a larger project.

I still believe a transfer case flipped around could work as a low cost way to turn a 5 ton Rockford into a 2 speed rear end for those wanting to use the (0.4/1 to 0.7/1 depending on the case)higher ratio to reduce rpm or whatever other reason a higher ratio could be used for.
A D18 is NOWHERE near strong enough for that though.

ALL your torque to the rear runs through this gear.



That cog on the top is what provides the torque to the rear... it easily shears off.



Here it is installed on the lower right for reference.



If it shears is causes this... The jeep is in 2wd high range and in gear, but obviously going nowhere.

http://smg.photobucket.com/albums/v4...=VIDEO0007.mp4

With all the weight of 5 tons... I am pretty sure it would shear the second you stepped on the skinny pedal of anything with any HP

FWIW I have abused the living shit out of my little jeep, running fairly close to stock CJ5 parts, and it has been rock solid. Renegade II has wheeled with me to know that, I think he has had to dive out of the way a couple times

His jeep is probably my dream Early Jeep.

Last edited by jeepfreak81; August 26th, 2011 at 02:41 PM.
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Old August 28th, 2011, 01:19 PM   #24
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Nice to know of that weak link. I am planing keeping to the basic design and switching out to slightly larger axles.

The 5 ton reference was just a example of a axle with gearing that would benefit from a gear reduction box.

It is pointless on anything that does not have gearing over the 8.-- range. And yes in that torque class a black lash would destroy the d-18 case.

I admit I was wrong to consider the d-18. It was just what seemed to fit at the time to make the 2 piece rear end work in a mechanical sense. Just one of the crazy ideas I had.
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Old August 28th, 2011, 09:58 PM   #25
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Originally Posted by cerial View Post
Nice to know of that weak link. I am planing keeping to the basic design and switching out to slightly larger axles.

The 5 ton reference was just a example of a axle with gearing that would benefit from a gear reduction box.

It is pointless on anything that does not have gearing over the 8.-- range. And yes in that torque class a black lash would destroy the d-18 case.

I admit I was wrong to consider the d-18. It was just what seemed to fit at the time to make the 2 piece rear end work in a mechanical sense. Just one of the crazy ideas I had.
I wasn't trying to bust your balls, I just wanted you know know that it isn't necessarily the gear itself that is the weak link. That damn cog burned my ass last summer, because it sheared so cleanly that I could not figure out where the damn t-case was broken. All the while it was right in front of me
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Old September 2nd, 2011, 11:04 PM   #26
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That's ok it is the advise I needed.

So I will toss out the cnc card for the heck of it. Lets say you were to "build from scratch" a 2 speed case. This is based off a design I had for a 2 speed transfer case.

I am just going to use a 1/1 and 0.5/1 ratio for simplicity. I am also not going to get into tooth count. All these gears are spur gears.

It would have a lower shaft and a upper shaft. It would have a shape like a D with the upper and lower shafts being next to the vertical side not the curved side.

On the lower shaft you would have a 3" tall gear towards the front. Towards the back of the lower shaft you would have a 1.5" gear. This lower shaft is one piece running a 1" shaft to the pinion with.

On the upper shaft you have a 3" gear that rides on a 1.5" shaft. This 3" gear is movable from front to back using a fork.

Towards the front you have a 1.5" middle gear that meshes with the 3" lower gear.

When the 3" upper gear is moved forward it meshes with the 1.5" gear then the lower 3" gear giving a 1/1 ratio.

Towards the back you have a 3" gear, that meshes with the lower 1.5" gear.

When the 3" gear is moved back it meshes with the 3" gear than the lower 1.5 giving a 0.5/1 ratio.

The 1/1 uses gears in a vertical layout

O
o
O

While the 0.5 to 1 uses gears in a D shaped layout

O
..O
o

This is a bad visual but you get the idea.

1/1 ratio
O(Movable input gear)
o(idler gear)
O(ratio gear)

0.5/1 ratio

O(Movable input gear)
..O(idler gear)
o(ratio gear)

I am not sure about seals though. But as far as making it work you could use stronger materials. You need all the gears to be spur in order to have the simplistic sliding input gear.

This case would be somewhere between 3-5 inches thick reducing drive shaft size but would move the center of the drive shaft up 4.5" inches which would cause less vibration overall(1/2 inch thick case 1/2 inch input gear 1" thick idler and ratio gears and 1/2 between the front and rear gears gives a 3.5" case).
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