Will someone explain how a dual t-case set-up actually works? Ive been looking into getting on, and think I will, BUT i jsut dont understand how they actually operate. For instance... dual, hense two transfer cases.. now is one for the front axle, then the other for the rear, correct? So how does it work to stay "stock 4x4" then to hardcore crawling?? for instance, I like how the stock t-case gears for light stuff, like mud, yet if i had a dual set up, that lowers it soo much, I dont want to crawl through mud like i would the rocks.. someone slap me, cause Im pretty stupid. Id appreciate it if someone helped me out..

go to www.marlincrawler.com and look around at every page.. then come bck and ask your questions :)

A Toyota transfer case is actually two parts, a low range unit and a 4wd unit. The two parts bolt together to make a complete transfer case. A dual setup is where you take a second reduction unit and bolt it to a complete transfer case. So you end up with two reduction sections and a 4wd section. The two reduction sections work sepratly. To add a second transfer case you will need the reduction half of a transfer case and an adapter. These parts go inbetween your trucks tranny and transfer case. Due to the entra length of the dual setup you will need to lengthen the front drive shaft and shorten the rear shaft.


Here is a photo of a dual transfer case ready to bolt up...


http://www.allprooffroad.com/bbs/8073.jpg

I'm only answering this because you actually asked up to play "SLAP THE NEWBIE" instead of acting like a know it all...

Basically, it's like slipping a 6.5" long box between your transmission and your current transfer case. It has a separate lever from your current transfer case, so you can activate either individually.

Shifting your t-case into 4-low gives you the exact same low range you have right now. You can then shift the "extra" t-case into low, and crawl 2.28 times as slow as you can now.

Also, since they are independently activated, you can leave your current case in 2-Hi and shift the second case into low range. So you have a 2 wheel drive low option as well.

yeah, I was just lookin there while I was typing that up. So, there are going to be your stock t-case gears, plus whatever ratio you order, hense.. thats what gives you the reduction, right? meaning you have your stock 4x4, plus the extremely reduced ratio too? As I was looking at martins pages, like with his set ups and all, he has single case set ups for sale i see, a complete t-case assemblies, who this bolt to the back of the factory t-case? or replace it?

scratch my last post..... heres my new ?, When I decide to do this.. what needs to be purchased? is there a complete kit that includes all the adapters and stuff? like Martins, the "complete tcase ass", is that all Id need to get? then, yeah obviously shorten the driveshafts?

thanks everyone

Originally posted by Chris Geiger
A Toyota transfer case is actually two parts, a low range unit and a 4wd unit. The two parts bolt together to make a complete transfer case. A dual setup is where you take a second reduction unit and bolt it to a complete transfer case. So you end up with two reduction sections and a 4wd section. The two reduction sections work sepratly. To add a second transfer case you will need the reduction half of a transfer case and an adapter. These parts go inbetween your trucks tranny and transfer case. Due to the entra length of the dual setup you will need to lengthen the front drive shaft and shorten the rear shaft.


Here is a photo of a dual transfer case ready to bolt up...

Actually Chris the tcase comes apart in 4 pieces really, hence people calling the reduction unit a 1/4 case. I know you know and I know I know, but I thought I'd toss it out there. :flipoff2:

Two things:

First, You'll need:
1. A second t-case (either geared, or stock gears)
2. tcase-to-tcase adapter
3. driveshaft work
4. new crossmember
5. cut hole in floor/cosole for new shift lever (you'll have three now)

Second, you need to decide how low to go:
You don't HAVE to go with lower gears. Toys have a 2.28 low range gear in the transfer case. So right now you have:
Tranny (3.93) X Transfer (2.28) X Axle gears (4.10, I'm guessing)

3.93 x 2.28 x 4.10 = 36:1 overall gear ratio.

36:1 is a decent crawl ratio for a stock vehicle, but not low enough for any time spent on the rocks, or even most steep hill climbs with a 4-cylinder. If you simply stack a second t-case between your tranny and transfer case, you get:

3.93 X 2.28 X 2.28 X 4.10 = 83:1

Now, when you add that second T-case you have the opton of replacing it's 2.28 gears with either 4.0 or 4.7 gears, which makes thing MUCH lower:

3.93 x 2.28 x 4.0 x 4.10 = 146:1
3.93 x 2.28 x 4.7 x 4.10 = 172:1

... As you can see, the lower t-case gears added to one of the transfer cases makes a big difference. Personally, I'm going to be adding a second transfer case without putting a low-range gearset in it for now. With 5.29 gears, I'll be at 108:1 overall... which is low enough for someone like myself who doesn't exactly wheel Johnson Valley every weekend.

Thanks alot TNToy, thats exactly what i needed. Hey, Chris, you guys have a crossmember for a dual case set up for a 82 toy, right?

thanks
chuck

Originally posted by TatonkaII
Thanks alot TNToy, thats exactly what i needed. Hey, Chris, you guys have a crossmember for a dual case set up for a 82 toy, right?

thanks
chuck

Yes we have the 82 single and dual crossmembers, $249

Originally posted by Chris Geiger
A Toyota transfer case is actually two parts, a low range unit and a 4wd unit. The two parts bolt together to make a complete transfer case. A dual setup is where you take a second reduction unit and bolt it to a complete transfer case. So you end up with two reduction sections and a 4wd section. The two reduction sections work sepratly. To add a second transfer case you will need the reduction half of a transfer case and an adapter. These parts go inbetween your trucks tranny and transfer case. Due to the entra length of the dual setup you will need to lengthen the front drive shaft and shorten the rear shaft.


Here is a photo of a dual transfer case ready to bolt up...


http://www.allprooffroad.com/bbs/8073.jpg

so which box to run up front, the stocker or the reduced box, im thinking seriously on buying your guys complete lift, i just read the install article in the 4wd mag of your 5 inch lift, great tech and good pics for a dumbass like myself to go by, ive seen here on the pbb some issues of customer service,, could someone like myself, who lives in interior alaska get good customer service and good tech assistance not that im special, just the fact that if i buy your lift, i want it all there in the box and it all to be correct items, it would be way too long turnaround on a simple mistake, the Ups man up here dosnt like to freeze his ballsac off for no reason at all,,,,,,,,later

put the reduction gears either 4.0 or 4.7 in the rear case.:eek: :D

or you can run 2.28 (stock) in both.

I would put the gears in the front case, I don't think that it really matters does it?

Originally posted by pitter
put the reduction gears either 4.0 or 4.7 in the rear case.:eek: :D

or you can run 2.28 (stock) in both.

whats the reasoning for running the reduced in the rear, what if u ran 2 reduced t cases would it matter,, just wondering:eek:

By running the 4.7 in rear and 2.28 up front the input shaft
to the second case will see less torque. Also, since you are
ordering 4.7 gears and a dual case kit you can order the rear pieces
in larger 23 spline at no extra charge.

Jay

how is shifter clearence with a bench seat on the rear case?

Chris---just looking at your pic there and noticed that the front case has a shifter bolted on top of it....is that just for demo? cause I see the 2 speed shift fork coming out the front for the "in the transmission " shifter.

My .02

If you are going to wheel in the mud and see very little Rock Crawling go with 2 stock gear sets. Sometimes you will need the extra momentum.

You need to buy a second case (from where ever) and an adapter (pick your source).

If you are not real mechanical seek some help I did with mine.

With the shifters you now have one that only does High and Low only
and the other does 2 HI , 4HI and 4 Lo

I'm still pretty new to tearing t-cases up, so maybe this is wrong but I heard on another board that I would need to cut some shafts in the transfercase. Is this correct?
I have an '84 and I've got extra tranny/tcases from another '84 and an '83 and I'm thinking of getting an adapter, having my driveshafts fixed and putting dual cases in. I just would like to be sure that I have everything I need before I tear into things.

Thanks for the help.
Josh

Originally posted by Ckretintimidator
I'm still pretty new to tearing t-cases up, so maybe this is wrong but I heard on another board that I would need to cut some shafts in the transfercase. Is this correct?
You may have to cut a little bit off of one shift rail, but no cutting of any main input or output shafts.

I have an '84 and I've got extra tranny/tcases from another '84 and an '83 and I'm thinking of getting an adapter, having my driveshafts fixed and putting dual cases in. I just would like to be sure that I have everything I need before I tear into things.
Go to www.marlincrawler.com and start reading. All the info you need is there. www.advanceadapters.com has a good page on their site discussing the advantages and disadvantages of using each year of case for a dual case setup.[/B][/QUOTE]

Thanks, I'll check it out.
I'm pretty sure I was told that I would have to cut an input or gear shaft, I'm glad that's not right.

Josh

It's good your asking questions, as did many of us at that time. I did it too, but just keep researching and reading. It won't make any real concrete sence tell you put it together right in fron of you....

Check Merlins site for his "crawler-installer" if not give them a call and see if they can send you one. Email me and I'll scan mine an make it a PDF, and email it to you... It answers a lot of questions, and explains the process for....well installing it :D

Originally posted by RightPedal
Two things:

First, You'll need:
1. A second t-case (either geared, or stock gears)
2. tcase-to-tcase adapter
3. driveshaft work
4. new crossmember
5. cut hole in floor/cosole for new shift lever (you'll have three now)Number 4 is really not required. You can run dual cases with stock crossmember

Also, don't forget about the cheaper solution, inchwormgear (http://www.inchwormgear.com/) His new site is really useful for explaining the various gearboxes and such.

Just another stupid question;

can you run a forward shifting case in the front pos. using the original shifter pos.(in the trans case) but limited to just hi-lo?

how is shifter clearence with a bench seat on the rear case?

Rear case shifter hit my split bench, so i would have to scoot my driver's seat all the way back to shift the rear stick. I solved that by sending my dad to the junkyard where he scored some pristine, newly-upholstered Recaros out of an 84 BMW. So now I can shift it with no problem and have all the bolster support i need! I just can't have anyone over 180 lbs. riding with me or they'll complain that their butt doesn't fit.

Originally posted by Dirtdragon
Just another stupid question;

can you run a forward shifting case in the front pos. using the original shifter pos.(in the trans case) but limited to just hi-lo? Good one:laughing: :laughing:

Originally posted by 1Badrocktoy
Good one:laughing: :laughing:

yeah, that was worth bringing this thread back up after 10 months. :shaking:

you do realize that was written in feburary right?

crap.. i knew this would come back to haunt me...

Originally posted by r0ckRnr


yeah, that was worth bringing this thread back up after 10 months. :shaking:

you do realize that was written in feburary right?

Auctully is wasn't feburary, it was08-02-2002 12:34 PM :rolleyes: If you are going to flame, get your shit stright:flipoff2: