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Old 10-19-2018, 06:41 PM   #1 (permalink)
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Marlin Crawler Heavy Duty Transfer Case Front Output Strength & Tech Article

As mentioned in our Newsletter, this is a short tech article for Marlin Crawler's 30-Spline Chromoly Front Output Shaft which applies to 1979-95 gear drive Toyota transfer cases.



Hello fellow Rock Crawlers!

Every year we see thousands of broken customer drive train parts and over the years we've seen some pretty crazy stuff. Carnage that makes ya scratch your head and wonder how in the world did that fail. Marlin has a nice section behind his office we call the 'Trophy Room', where he has been saving broken engine, transmission, transfer case, and axle components for years and years.

One man's junk is another man's treasure

Nine out of ten customers could care less about their broken cores and any day we get to add broken parts to our collection is a great day. You should see how excited we are when we come across these things. In fact, just since May of this year I've amassed an amateur collection of 5 failed late-model Tacoma & 4Runner IFS inner tie rods that I've encountered out on the trail. You guys will be seeing them in our marketing once we get our Heavy Duty IFS 'MarRack' steering system into production next year. Our IFS tie rods are a minimum 2.5-times stronger and are holding up to my 40" tires + Triple Transfer Cases with ease. Being able to show side-by-side comparisons of parts to customers on the trail is a real eye opener.

Thank you Marlin the pack rat

While cleaning we came across some broken factory 1979-95 gear drive t/case front output shafts Marlin had saved in a box. Out of the collection, half failed at the splines and the other half failed at the smallest cross-sectional area past the bearing race. We expect more would fail at the splines due to additional lateral forces created by the front drive shaft, but it is nice to see failures beyond the bearing at its smallest diameter.

Here is one of the factory front output shaft failures that occurred at the splines:



And here is the other failure from the smallest location beyond the bearing (smaller than the splines). The keen eye will note Marlin's handwriting of Mr. Cole. Thank you Dave for the trophy!



And finally, here is the Marlin Crawler Front Chromoly Output Shaft comparing cross-sectional area Vs. the factory Toyota counterpart. For all you gamers out there, this is straight-up OP:



Not only has the spline failure region increased by 25% and the minimum cross-section failure region by 67%, but we are using Chromoly steel which itself has a higher yield strength. Lights out, Game over.

Another thing to consider is that the flanges of each broken output we have are all re-usable. Therefore, this sample set shows that flanges are stronger than the shafts, and in our experience this is what we have witnessed out on the trail.

But when we began testing early HD prototypes in a Toyota V8-powered King Of The Hammers competition vehicle, we found our shafts were so strong that a factory Toyota flange could not hold up!


First time we had ever seen this! Test flange is from a 5.7-liter V8 Tundra

This is why we had to manufacture uber high strength flanges: Marlin Crawler oversized Chromoly outputs are that strong.



We designed these the sensible Marlin Crawler way with a 135% thicker cross-section, longer splines for maximum engagement, and a custom HD EcoSeal to boot



A strong case for the strongest output available

We have been selling Oversized & Heavy Duty Chromoly Toyota Transfer Case Outputs since 2008 and still to this day are the only upgraded outputs that are so strong they necessitated upgraded flanges obliterating two weak-links with one product!

If you were wondering what output shafts are the strongest, this point alone provides heavy credence to the case.

Thank you for reading and Happy Crawl'n!

Regards,
BigMike
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Old 10-19-2018, 09:03 PM   #2 (permalink)
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I have been eyeing the marlin outputs for my project. Hopefully I will have enough funds for that.
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Old 10-20-2018, 12:59 AM   #3 (permalink)
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heres a 30 spline whoopsie

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Old 10-20-2018, 03:54 AM   #4 (permalink)
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Sweet. Another product that will continually be on backorder. Id spend more time trying to locate parts that your customers want instead of doing write ups on said product.
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Old 10-20-2018, 05:21 AM   #5 (permalink)
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Additonal lateral forces of the front driveshaft....

Yeah ok.
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Old 10-20-2018, 07:19 AM   #6 (permalink)
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Does anyone know the oem part number of the seal they are using on their 30spline kits? I need to source one locally so I don't have to wait a week to get one, and it's a 50/50 crap shoot if the right parts are even in the box.
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Old 10-20-2018, 08:55 AM   #7 (permalink)
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Quote:
Originally Posted by eat.sleep.wheel View Post
Additonal lateral forces of the front driveshaft....

Yeah ok.
driveshaft not only hangs off at an angle beyond the splines, but fronts commonly get dragged on rocks, maybe more than rears even, and square abusive shafts are more common up front as well.

i dunno, statement doesn't seem outlandish to me.

either way, thanks again for posting up a nice tech article big mike

i've personally never seen the appeal for the 'heavy duty output flange' but i've also not seen the failure you posted before.
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Old 10-20-2018, 11:23 AM   #8 (permalink)
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driveshaft not only hangs off at an angle beyond the splines, but fronts commonly get dragged on rocks, maybe more than rears even, and square abusive shafts are more common up front as well.

i dunno, statement doesn't seem outlandish to me.

either way, thanks again for posting up a nice tech article big mike

i've personally never seen the appeal for the 'heavy duty output flange' but i've also not seen the failure you posted before.
id have to take it apart to get a better idea of why it broke like that, it very well could have been from a rock on the drive shaft.

when i took that same case apart to install that 30 spline output the stock one was had a crack and twisted splines about to break.
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Old 10-20-2018, 11:43 AM   #9 (permalink)
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id have to take it apart to get a better idea of why it broke like that, it very well could have been from a rock on the drive shaft.

when i took that same case apart to install that 30 spline output the stock one was had a crack and twisted splines about to break.
even just the nature of how they are assembled and where the bearings are relative to the joints, if the front tires are bound up and the stress is going through the gears, consider the angle that is now being twisted/applied to the shaft/case/bearing/spline.

the gears are trying to push away from each other inside the case. The shaft is held with bearings at the rear snout and in the front, behind the splines. The driveshaft is trying to push the shaft up and away because of the joints.
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Old 10-21-2018, 03:00 PM   #10 (permalink)
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Hey Mike, it sure is refreshing to look at the site and see items actually in stock and available. This was a much needed push, and took a while to get there. Thanks for stepping up.
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Old 10-21-2018, 03:01 PM   #11 (permalink)
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I plan on purchasing both output kits for my truck once I get the other major purchases out of the way.
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Old 10-22-2018, 06:08 PM   #12 (permalink)
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Thanks for the innovation and looking forward to the MarRack. Mine (98 runner), is hanging in there for now, but I expect that to change at some point.
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