Outer Limits 4x4 Board

Hi Frank
How did new years go ,have you recovered yet.
Is there a non super select box that the 2.85 transfer gears fit, I was
thinking maybe L300 , which I could put on the rear of my 94 V6 manual.
I want to lengthen my drive shaft , And I was thinking about a Slip Yoke Eliminator ,but the gain in the SS box is minimal.So I was wondering if there was more to gain without the viscous hub in the tailshaft housing.
J Top

G'day Carl, yeah I just had a quiet one for new years.
With the SYE this is one thing I'll be watching very closely on mine now.
The rear tailshaft has a 30mm spacer at the diff flange for maximum spline engagement. The front shaft has been lengthened a bit and just has the Toyo pinion flange at the diff end with the Mitsu slip yoke at the t/case end.
During flexing trials everything looked fine and there was at least 50mm spline engagement with each shaft at maximum travel.
However a few Yanks have reported severe vibrations when in hi range at over 20MPH they think due to the play in the front slip yoke assembly.
Both guys have had custom SYE kits installed by drilling and tapping the front output shaft (there already is a pilot hole there) and modifying the slip yoke with a flange that can accept a 20mm long x 0.5" bolt.
One of them is running a DC joint as well and both guys report the vibrations have totally gone.
The SAS done on the Gen 2 swb by ORI in Sydney had this done as well using a Hilux DC shaft. Looking at mine it wouldn't need a DC joint a standard uni would be ok as the high pinion centre reduces a lot of the angle. If it was a low pinion then a DC would be mandatory.
ORI said drilling and tapping the hole was no real drama.
A Triton 3.0 V6 or Paj non super select 3.0 V6 case will take the 2.85 gears and save you about 4" in t/case length so a longer rear shaft can be used.
If mine carries on I'll be doing what ORI did and I reckon that's the go. The rear seeing yours is a swb Gen 2 may need a DC joint if your going way up, mine is at the limit now with the standard uni at the t/case end (pinion angle is spot on). If I want to go any higher it will definitely need a DC rear shaft.

Thank you for all that excellent info Frank,I will start chasing trans cases
J Top

Frank
Thank you for the compliment on my SAS thread.
Since I am changing the transfer gears, does that mean I can use the T/C out of an auto as well?
Also did you go to the 60 drop arm for the hilux TRE or to reduce turns lock to lock to make up for the 30mm difference in the stg arm @ the wheel.
J Top

Yep auto is fine, gears will fit.
The 60 Series pitman arm was the only one we could find that could be re-splined out to suit the Mitsi shaft.
To fit a Toyo or Nissan steering box would have required quite a bit of stuffing around. I wanted to keep it as standard as possible.
The Mitsi shaft is a course spline where as Toyo/Nissans are a fine spline.
The 60 Series arm has a slightly smaller diameter hole than the Mitsi arm so just enough meat to re-spline it to suit the Mitsi steering box.