Outer Limits 4x4 Board

Yes it is just as feasible with an auto, maybe more so because you could replace the existing auto spudshaft with a longer one that will reach right through the transfercase and into the reduction unit. This would save the trouble of boring the splines out of the transfercase input gear.
Bill.

yes I am looking at it with a ZF auto aswell.... there is to much info in this thread already my head hurts

Looking forward to seeing the pics Bill.

So who and how much do I pay? and when do I expect it in my hands?

will have both the q/trac and LT230 on table next week.
Trying to aquire a zf-lt spud shaft this week.

will see what comes next.

This will happen just not quickly. If any one else is doing PM me so that we can move forward together, just may make things easier for all.

Michael.

Hi All.
Here are some of the photos of the crawler.

1. Output Gear LT95
LH Standard Fairey Overdrive LT95.
RH Modified for Crawler.





2. Output Gear Series
LH Standard Fairey Overdrive Series 1,2,3
RH Modified for Crawler.





3. LH Standard Fairey input shaft.
RH Modified for Crawler.





4. Modified Input Shaft with Bearing.





5. LH Modified Input Shaft.
Centre Standard Mainshaft Adapter Fairey.
RH Bronze Bush Replacing Roller on Mainshaft Adapter.





6. Assembled Crawler with SeriesOutput Gear.





7. Cut Front Section of Fairey Overdrive Case.





8. Rear View of Cut Case.





9. Adapter Plate with Front Section of Fairey Overdrive.





10. Rear View of Adapter Plate.





11. Side View of Bill's Grubby Finger and Adapter plate.





12. Rear View of Crawler on Series Transfer Case with Handbrake
Backing Plate.





13. Top View of Transfer Case with Crawler Attached.






Bill can provide full descriptions and more detail.

I hope this provides some idea of the modifications.

Regards

Nigel

Great pictures, thanks Nigel!!!

Bill on the series fairey have you ever had problems with the small teeth on the mainshaft inner gear wearing out like the overdrives had - or is there a modification to provide better lubrication???

Thankyou Nigel for posting those for me.
These photos should give anyone familiar with the workings and operation of fairey overdrives a reasonable idea of how the reduction unit is adapted.
Photo 1 shows a modified LT95 Fairey output gear beside an unmodified one. The old helical gear teeth are ground off and the splined section of the quadratrac upper sprocket is cut off,bored out and pressed onto the Fairey output gear and welded on. I haven't welded this one yet.
Photo 2 shows much the same thing but these are off my series 2a Landrover.
Photo 3 shows the modified Fairey input shaft beside an unmodified one.
as can be seen the shaft has been chopped and replined to engage with the quadratrac input gear(sun gear). I had the splines ground in at a precision grinding works to save annealing the shaft. Although the spline lands (sides) are not case hardend they do not wear at all. The shaft is also rifle drilled and further modified to improve oiling for the mainshaft adaptor splines.
photo 4 just shows the shaft with some of its bearings in place.
Photo 5 shows the shaft with its matching mainshaft adaptor. On my vehicle I have replaced the roller bearing on the mainshaft adaptor with a bronze bush because I have found that the rollers Brinell themselves into the bore of the output gear due to the fact that when the crawler is in high range (98% of the total mileage) both input shaft and output gear are locked together.,
Photo 6 shows the assembled crawler box .
Photo 7 shows the front section of a scrap Fairey gear housing that has been sawn off and machined flat.
Photo 8 is a rear view of same.
photos 9, 10 and 11 shows front side and rear views of the adaptor plate.
Photos 12 and 13 shows the crawler attached to an empty series 2a transfercase. The crawler is a tight squeeze for a Series, and part of the handbrake backing plate must be cut away as shown, and the handbrake drum rim machined slightly to clear the crawler housing. Drum is not shown.The aluminium plate and splined dog at rear is my PTO adaptor to drive my winch
Bill.

In the November issue? of Australian 4wd Monthly on page 104 there is an article on the GkN overdrive for Lt230's. On page 106 there is a clear picture of the transfercase input gears both standard and GKN. The GkN gear is very similar to what the standard gear should look like after it is modified to suit the Quadratrac reduction unit.
Amazingly the overdrives sell for around AUS$4000 and are not considered strong enough to be used as a split shift. Who buys these things ?
Bill.

This is a picture of the Rocky Mountain overdrive

If you can supply all of the modified parts needed to bolt this to a series transfer case, i will buy one from you right now. I can supply the low range box stateside (found one in good shape for $30 US), but am fairly lost on the modifications necessary. i also don't have a scrap fairey to use as a donator.

please let me know... i would require input/output shafts, as well as the adapter between the two. again for a Series transfer case.