Outer Limits 4x4 Board

Well just spoke to Mark Hardman before and the 20 sets of 2.85 gears will be ready next week (they are at the heat treaters now and then just need the final grinding).
Our aim is to get mine installed for the Pajero Challenge.
With twin lockers and the JT2's the traction is superb but it's the low range gearing that is holding the car back. Sure would be nice to idle over stuff rather than crash and bounce trying not to stall

Hi Frank

Good news about the gears, and good luck for the Challenge - I want to see a write-up on the Jabber-mobile in 4WD Monthly!

I emailed Mark about a set, but didn't get a response. Does this mean they are all spoken for or can I order a set through you?

Scott

Is yours an auto or 5sp ?

5 Speed

Yep there are 15 sets for the 5sp and 5 sets for the auto.
The auto's are all spoken for but there are some 5sp sets left.

Can you put me down for one?

Please

No probs, 1 x 5sp set for you

Frank.

Excellent!!!

Second best news this year!!!

What's the charge on the 5speed cogs? Are they suitable for the NL 3.5's manual?
Thanks
LJ

No unfortunately they don't fit the 3.5 V6 and 2.8 TDI (larger t/case).
These gears will fit all 2.6 and 3.0 V6 t/cases.

Frank

I've had two thoughts now that I can see myself with a decent low range

1. What's involved in fitting the gears - I'm confident about getting the t/c out, but should I be sending it away for the fitting, and how much should I expect to pay?

2. With more torque at the wheels are CV joints likely to be an issue?

Any thoughts?

Thanks,

Scott

Cool!
I just emailed Mark and asked him to put me down for a set (5sp) Can't wait.

Why only 5 for auto. In US the 5spd is almost non existent

Bitsamissin wrote:No unfortunately they don't fit the 3.5 V6 and 2.8 TDI (larger t/case).
These gears will fit all 2.6 and 3.0 V6 t/cases.

Will they go into the mazda b2600 with 2.6 (mitsui made the G6 engine and maybe the transfer case but not sure)? box is 5sp

Help! I haven't got a reply from Mark Hardman, they haven't all gone yet have they ?

I spoke to Mark today, they are flat out................
The gears are now ready and he just has to pick them up from the grinders. I'll be seeing him on monday to pick up my set and hopefully we can do the install and take heaps of pics for everyone else as a guide.

Frank.

Ok the 20 sets are now ready, picked up my set today
We have started cleaning up my spare t/case and will install them this week. I'll take heaps of pics as we go and write up a detailed install report.

They look like jems Frank, right on man.

Well Baz has cleaned up my old t/case and should have it all back together by the midle of next week.
Here's a couple of pics.
I'll keep taking them as we go to help with install instructions.
Once this case is assembled just to make sure there are no unforeseen problems they will go on sale.

Cleaned up super select t/case.



You can see the new larger low range gear just fits through the internal bearing hole inside the case.

Yes my t/case is 80% assembled now and the good news is....................
There are no modifications needed to fit these 2.85 gears into a 5sp 3.0 V6 super select t/case. It is just a standard tear down and reassembly using the new gears.
We found with the 2 x Gen 1 t/cases we had to machine a little off the hi/low selector fork to clear the new larger low range cog. Maybe the forks are different between Gen 1 & 2 ?? I'll check the part no's later.
I would also say that a Gen 2 auto should be the same as the 5sp (no machining required).
The new t/case will be installed by next wednesday just in time for the Pajero Challenge.
I'll post some pics tomorrow.

What is the difference in gears for Auto v Manual.

The difference is in the input gear (the low range and idler gears are identical for auto & 5 sp). The auto input gear is 23 spline and 30.5mm internal diameter it is also 3mm or so longer as it slides through a seal in the back of the auto. The 5sp input gear is 24 spline and 22mm or something internal diameter.
My t/case is now assembled and will be installed early next week.
No mods required you can see in the second pic that in low range the selector fork clears the 2.85 low range gear by about 2mm. Lloyd's and Patrick's cases needed the selector forks machined back about 5mm to clear the new larger 2.85 gear when in low range.

I have a line on a cheap 3.0 V6 super select manual t/case in good condition.
Who would be interested in a rebuilt case with 2.85 gears on a changeover basis.
Price would have to be around the $1800 mark exchange.

Hi Frank

I'm interested, but I'll need time to convince myself the extra $700 is good value. I'm still in the stage of convincing myself the gears alone are a good investment, and I'm trying to ignore the costs of installation

Cheers,

Scott

As owner of one of these cases I must say the difference from it and the stock case is amazing compression braking and just the greater crawling ablitiy is just a step above man. If anyone needs an extra 5 spd case i have one outta a 85 montero that the tranny burned up on. Frank thats great news on the fact there is no cutting needed on the gen 2 cases i'll pass that info on at our club meeting.

Hey Patrick long time no hear dude.................
Howz things goin over there and how is your 2.3 turbo build up going ??
I think Swartzy is winning on points now, 3" body lift, talkin about diff drop down brackets and superchargers

Frank.

Bitsamissin wrote:Hey Patrick long time no hear dude.................
Howz things goin over there and how is your 2.3 turbo build up going ??
I think Swartzy is winning on points now, 3" body lift, talkin about diff drop down brackets and superchargers

Frank.

Yeah but Trunk's truck is uglier... + 20 ugly points.

So Frank are these the last made ever, or is there going to be a run of them sometime in the future?

Yea lloyd's truck just keeps getting bigger been sometime since i wheeled with him. Talked a bit with him couple weeks back think we gonna hit up some trails together here soon should be some nice carnage. Right now i've still got a 2.6 in my truck me and my roomates all drive mitsu's so and share projects next one is taking the large collection of 2.3 diesel stuff we have an buying another montero and dieseling it we've only got 2 spare engine blocks and just about 3's and 4's of every part on it hehehehehe

Bitsamissin wrote:Yep there are 15 sets for the 5sp and 5 sets for the auto.
The auto's are all spoken for but there are some 5sp sets left.

Hi Frank, I am also interested to get one set for my 5sp manual. Pretty please with sugar on top, reserve one set for me.

Mate this thread is over 5 years old. Get in contact with these guys.

http://www.marks4wd.com/products/gearma ... -gears.htm