Outer Limits 4x4 Board

After rolling around in the mud by feeble torch light with gear oil dripping in my face, I finally pulled the transfer case off the back of my 4 speed F50, and things aren't looking good.

I've cleaned up all the bits, and it looks like I'm going to need to replace just about every gear and shaft, except for the input shaft, and while I'm at it, put in all new bearings and seals, which I expect will cost a small fortune, and quite possibly a large one as well.

Has anyone got a spare transfer case?
Or know of a suitable substitute?

I was hoping to do a 5 speed conversion in the near future, so the idea of spending massive $$$ on repairing a transfer that will just be replaced when the 5 speed goes in doesn't thrill me at all.

Also, does anyone have a manual or parts diagram for the transfer?
I pulled the case off, leaving the gearbox in the car, and everything kind of came out all at once, so I'm not sure how to reassemble it just yet.

Thanks for your help!
Soon I will hatsu again!

Welcome to the board. Easiest way is swapping a 5sp gearbox/tranny combo from an early rocky (mechanical operated transfer instead of vacuum/electric) as they are the same. I believe 3rd gear ratios are slightly different. Other than that it's straight bolt in swap. Don't forget to swap speedometer pickup from the old transfer as the rockies came with different diff ratios.

cheers, Ron

So to fit a 5 speed rocky box, I'd have to find 5 speed drive shafts, preferably from a diesel, as per this link here:-
http://www.outerlimits4x4.com/PHP_Modul ... hp?t=36410

My next question is: What is the handbrake set up on the Rockys?

On my F50 it's a drum brake on the back of the transfercase, acting on the rear drive shaft, and I was told by one local wrecker that the rockys had a different set up, leaving you with no hand brake if you swapped to a rocky box and transfer.

Thanks!

Hadn't thought of the parking brake issue
I know on the later Rockies thee were on the diff for sure, earlier I don't know. I have a spare box in the shed, so tomorrow I'll see how the little drum is attached to the output flange.


EDIT:

Drum assembly is bolted to the back of the transfercase. The casing in the back is identical but the output flange on the rocky is shorter. Guess the splines on the rockybox are the same(only got a pic from a rocky box..) Best thing is to find somebody with a spare rocky box on OL who can verify this. Maybe it's easier to swap rocky drum brakes on the rear