Zuk on 38's

Purchased the UK 6.1 Transfer Case Gears

Thought I would share some info on the 6.1 Transfer Case gears with the 24% high gear reduction since there doesn’t seem to be any reference info to be found.

Wanted to purchase the 8.1 TCG with the 24% High Gear Reduction unfortunately they were not available for 2 years. Ended up with the 6.1 instead and had the same high gear reduction as the 8.1 TCG.


The not so good:

These particular gear sets are only offered in the UK and shipping is pricey. There is very little info provided from the manufacturer on the gears and there are no installation instructions provided to show the clearance procedure. You will need to purchase a complete rebuild kit from one of the venders because you only get the gear set, gaskets and some squashed seals. These gears will probably show up with surface rust on them because of environmental conditions in the UK.


Clearance the housings::

The 6.1 Countershaft Gear is a bit larger then the Trail Gear 6.5 Countershaft Gear. There is a need to clearance the case for the gear to fit.

The Mill was the tool of choice used for these reasons:
Maintaining a consistent radius to a determined depth.
Large amount of material being removed.
Thin walls after machining.

( There was about 3/16” removed from the side wall and about a ½” depth. This gave about a .050 clearance all the way around on the machined surfaces.)

Here are the housings being machined for the Gear.

Short Housing Pics.

 

Large Housing Pics








The break through hole will be taken care of with a set screw with thread sealer theaded in from the opposite side. Yes if your thinking that is very close. Took it to the limit to not weaken the housing or cause an outer break through.

Going to be using a Zor Snatch to strengthen the unit and will help with the extra material that has been removed from the housings.

 

Fitting the ZOR Snatch

This is my second ZOR Snatch and did the wrestling match trying to get the bolts in on the 1st one. Hopefully you decided to get one when you are doing a gear replacement. This makes it much easier.

Here are a couple of steps that may make it much more enjoyable to install the ZOR Snatch on the case. This is a trial fitting and will need to be removed to install the gears.

 

Dual Pass Aluminum 15” Finned power steering cooler mounted to the under side of the stock round cross member.

 

Here are a few things that were made or hooked up to tidy up the engine compartment. Have a long way to go yet.

 

Update with pics:

Since there was some confusion and I don’t speak good redneck yet. I will just go back to the old way of posting.

Parts Removed again for some adjustments to the Upper Front Spring Mounts




This mount was store bought and was never happy with it because of the thinner material used. New this was going to be cut off later so it was used just to get things started.




This pic is to show the layout of the original mount the new mount location and the frame extension that was welded on parallel to the ground

The shackle angle had settled in at 36* and about ¾ “ lower then when it was set up with the guesstimated weight that was added when 1st setting it up.

With the addition of a few more items and some added plating this is what lead to the adjustment being done now. I would like to be back at about 25* shackle angle. This will also bring the original height back as well.




Here are a few pics of the Nw Font Upper Spring Mounts in different stages of being made.







Going to try and get the old mounts cut off tomorrow. Went from way too hot to raining all day. Will need to make some location bumpers to get the mounts back to the proper width and a 43” length eye to eye bar for the length.

 

Back on all 4 again.

Got the old front spring mounts cut off. The new front spring mounts were repositioned ½ “ further up on the frame extension to a mounting dimension of 42 ¾”. This is still shy of the 43” dimension that the YJ uses for their mounting position.

This did not affect my caster angle or any of the other suspension that was setup previously. This has been all double checked now and all is good. The shackle angle is now set to allow for some additional passenger side suspension parts and some spring sag.

The reason again for moving the spring mounts forward was to bring the shackle angle and the height back to where it was originally setup. The first spring mount dimension was just a base line to get the suspension started.












Here is a removable bump stop aligner that was made before removing the old spring mount. This was used to transfer the same mounting position but moving it ½” forward. This tool was also removable since the old mount still needed to be cut off.









Time to finish up the modifications of the transfer case mounts.

 

Here are a couple of pics of the High Back PRP Suspension seats. They are a close match to the new panels that had been remade.

 

Thats it for awhile

 

Every time I see this build it's even better Awesome work

 

This is the first time iv'e seen this build....all i can say is WOW!!! Truly amazing. I applaud your talent and skills...can't wait to see more.

 

Amazing work, excellent attention to detail and great explanations and insight to the process behind the madness.

 

JLee
MJM777
nOrth

Thanks for taking your time to look in on my build. Just trying to make it interesting and easier to understand with the extra captions in the pics.

Greatly Appreciate the compliments as well.

 

I have a running tab on the build and have just about got to the amount that I wanted to spend when I 1st thought about building it. Very important to try and get a good approximation of your budget before starting.

The intake alone was 260 hours cut out of a solid block of aluminum. Really don't keep a running tab on my build time. It is just a hobby to keep me busy. If I wasn't working on this one probably have to start another build.

 

Thought I would update with a video. Yes, it is running but not completed yet.


If you would like to keep up with the build you can check this link.

http://www.zukikrawlers.com/showthread.php?t=44942



Here is the video

http://s1086.photobucket.com/user/TanZuk/media/Its%20Alive%20Video/Edited.mp4.html

 

Just awesome work man!

 

This shit is sick as fuck