Sifu-Lux's Project Dual Transfer Case

[missouriman]

great job, looks awsome.

looking at that it dawned on me, I don't think I could shift with my left hand.
or it would take a lot of getting used to.

[chopper]

Mark, how about getting a pretty girl next to you to do all the shifting for you -with the right hand?!
Easy solution!

[Mud Dog]

Thinus, Mark's wife is also an extreme offroad enthusiast with her own vehicle ..... She would not be pleased.
See Mark's thread here
viewtopic.php?f=92&t=6705&p=74191#p74191
The blue Lux is Mark's ... the pink one is his wife's.

[chopper]

Eish! How do I cancell?
Sorry Swaer!

[Mud Dog]

Eish! How do I cancell?
Sorry Swaer!

No need to 'cancel' .... Mark won't take offence.
Did you look at the photobucket pics as well, Thinus? ... if not, go back and look. Very interesting!

[chopper]

Thanx Andy,
I looked and enjoyed it!

[Sifu-Lux]

Andrew

Great workmanship and job well done

Will it be seen on Thursday Night at Outdoor Warehouse?

Zane

Probably come in my platkar BM as I'll come straight from work. I can't leave the Hilux out in the elements all day on it's own

We may go play on the weekend, we can chat to Barto, as he is keen.

[missouriman]

Mark, how about getting a pretty girl next to you to do all the shifting for you -with the right hand?!
Easy solution!

HA, if she grabbed the (wrong) shifter I might drive right into a tree!!

[Sifu-Lux]

So, as they say, the proof is in the viewing

Tested everything yesterday, and all I can say is UNBELIEVABLE

Pics here: http://www.zantusdesign.co.za/gallery2/ ... emId=41721

Video Clips here: http://www.youtube.com/user/ZantusDesign
(See lower left of screen for all they clips)

[Mud Dog]

I looked at that gallery when you posted it yesterday .... there seemed to be a lot of repetitious pics! I thought to myself as I looked at them from the beginning in the flat area "Andrew must be itching to engage that 2nd X-fer" (I also thought as to why the guy in the Paj was having such an issue with that small rut in the road ... even kicked up dust! :wth: ). Then of course from about pic no 112 I saw you would have had at least 3 opportunities to use the 2nd X-fer. Haven't watched the videos yet. (Looks like the next project is going to be articulation improvement! ... I need it too!

[missouriman]

nice pictures and movies.

here are some things you get to look forward to with the control of the dual cases...










as for articulation... wheel movement is relative!!!!

















Pretty shifter women!

[missouriman]

just wondering....

is it weird, strange for you guys to see the steering wheel on the wrong side???? for us the left side. thinking about shifting with your right hand?

[Family_Dog]

I was wondering about shifting with my right hand. Although I am right-handed, I guess I would battle... shifting with the left hand seems so easy & natural now!


-F_D

[missouriman]

Eish! How do I cancell?
Sorry Swaer!

No need to 'cancel' .... Mark won't take offence.
Did you look at the photobucket pics as well, Thinus? ... if not, go back and look. Very interesting!

HAHAHA .... I love seeing pictures of the other side of the world.
I am very glad that I stumbled on this site. chatting with others ON THE OTHER SIDE OF THE WORLD!! that is just crazy. love this internet stuff.

I don't want to thread steal.. should I start a new post...?

love this build up. love keeping it as toyota as possible. I think we have the only rock crawling toys here in the black hills of south dakota. all the rest have gone v8's, changed axles, just about every thing but the body and frame.

we have a motor with little power. other then that draw back, (that is to mean that the motor will not break other things. a good thing). we don't have to fix the truck every wheeling trip. I end up pulling out other trucks almost every time we go out. Do you have the Jeep there? I pull those out every time we go out. Jeep owners just hate toyota owners... as they always end up on the wrong end of the strap. I don't think I have ever been pulled out by a jeep...... just once that I can think of by a big ford truck. hit a ditch that was about 3 feet wide and 6 feet deep....

do you guys get snow? that is alot of fun.

http://www.youtube.com/user/SBSDubStyle ... lDM_CtYExw

pulled out two jeeps at the same time.

[missouriman]

I was wondering about shifting with my right hand. Although I am right-handed, I guess I would battle... shifting with the left hand seems so easy & natural now!


-F_D

see that would just be so wrong for me. over and up and away for first... to me and down for reverse....

[Mud Dog]

Hi Mark, no need to change threads .... it's all transfer case related.
Once again, some really awsome pics! .... and yes we get the Jeeps here too ..... and I don't think they like the Toyota guys here too much either! .... loved the video clip!

As for the LHS /RHS drive thing, if you're just cruising along with only one hand on the wheel, which is it? ... the right hand if you're right handed (for the vast majority of us). To me it stands to reason then that it's more natural to steer (generally the more important function) with your right hand, leaving your left free to shift, (generally the lesser function). I guess it boils down to what you're used to though.

[missouriman]

just going down the road.
left hand on wheel.

wheeling in the rocks.
both hands with the thumbs up, so if the wheel spins hard I won't break my thumb.
even with the hydraulic cylinder assist I have had the wheel spin hard and fast enough to break my grip.

[chopper]

Hi Mark,
Thank you for the good sense of humour!
You posted some awesome pictures - going up the "waterfall"; unreal!

[Mud Dog]

wheeling in the rocks.
both hands with the thumbs up, so if the wheel spins hard I won't break my thumb.
even with the hydraulic cylinder assist I have had the wheel spin hard and fast enough to break my grip

This is of course common sense and should be standard practise, but I still find myself sometimes hooking my thumbs when I'm not thinking about it.

[missouriman]

one spin and thumb pointing at your elbow and you won't forget again!

recently I used foam pipe insulation, electric tape, a fake leather steering wheel cover, and used parachute cord instead of the plastic wrap cord.

padded the steering wheel so it is about an inch, maybe inch and a half across.
the fat wheel reminds you to thumbs up. gives you a bit more to grip onto.

[Mud Dog]

Good idea .... even just binding the wheel with cord will give a different feel and keep one aware. Might even help with grip as well.

P.S. Cannot see so nicely on your pics, but it looks that you have done away with the steering damper on your cross-over steering?

[missouriman]

Yes, Steering damper is gone..
replaced with this.


clean up frame for braces


cylinder hose 1


Cylinder hose 2



cylinder for hydro assist.







old brackets have been trimmed off..




sure makes the steering in rocks alot easier!!!!

[Mud Dog]

Mark, explain! .... I see you changed out the steering box and converted to cross-over steering. What I cannot fully understand is that you've taken hydraulics from the steering box to a hydraulic ram on the tie-rod, yet your steering box is also connected with a pitman and drag-link. Essentially it looks like you have a duplicate steering mechanism.

Is this done as an "assist" and if so, how did you synchronise them that one doesn't "fight" against the other? ..... or is the hydraulic pressure balanced between the two systems in that they share the same pump?

[missouriman]

Mark, explain! .... I see you changed out the steering box and converted to cross-over steering. What I cannot fully understand is that you've taken hydraulics from the steering box to a hydraulic ram on the tie-rod, yet your steering box is also connected with a pitman and drag-link. Essentially it looks like you have a duplicate steering mechanism.

Is this done as an "assist" and if so, how did you synchronise them that one doesn't "fight" against the other? ..... or is the hydraulic pressure balanced between the two systems in that they share the same pump?

Wow, that is a tough one to explain, so bear with me here.


all the pressures are controlled with in the steering box.
I drilled and tapped into the pressure passage ways in the steering box.

so just as when you turn the wheel the power steering helps you turn.

I used this pressure help to apply additional turning force by using the cylinder.

these are not measurements at all, just numbers, OK!!!

lets say that I am turning left.
the pump helps me turn (stock steering box) with 500 pounds pressure.
this pressure is turning the steering through the steering box shaft.
this is reduced by the length of the steering arm on the box. but we will leave that reduction out for now.

now after drilling into the box and routing that pressure to the correct side of the cylinder it also gets 500 pounds pressure.

so now instead of 500 pounds pressure on the tie rod it can see 1000 pounds of turning assistance.

when I let go of the wheel and it is returning to center there is no pressure in either direction, same with the cylinder. so even the return to center works.
just a tiny bit slower due to pushing the oil out of that side of the cylinder.

the only time the steering is slow is below 700 RPM. due to the additional fluid that needs to flow to meet the needs of the steering box and the cylinder.
at or above idle, you can not tell any difference.

I used a 6 inch ram, what would be perfect with the length of steering arms that I have would be a 5.5 inch.
due to the flow and volumes I picked out a 1.5 inch (inside diameter) cylinder with a .75 inch ram ( the part that sticks out, moves back and forth).
I had to increase the size of the oil reservoir by about double. this is due to the volume displaced by the 6 inch .75 inch ram shaft.

I used a 4 inch ram on my wifes truck and did not need to increase the reservoir size.

I also used a small oil cooler in the return line due to the additional work load on the pump. I also drilled out the re-stricter on the high pressure side of the pump just a little bit.

so now when turning normally there is hardly any delay, when turning in a hard spot the pressure will build up to what ever maximum is.

they cylinder helps the wheel not get ripped from your hands, and acts like a stabilizer.

in a situation where you could not turn the wheel with both hands with stock steering. you can turn with just one hand with the cylinder. on loose gravel it can slide the truck side ways.

with the cylinder and pulling on the wheel with both hands you could break tie rod ends. I used the much larger late model land cruiser tie rod ends.

total cost of the assist up grade (not including cross over steering or the steering box) was about 120.00 dollars
have to drill and tap two holes in the steering box, I made my own cylinder mounts, and two hyro lines.

with both systems in place and the motor not running it also takes about twice (or more) the effort to steer it manually.

there are some great articals out there on how to drill the box. one hole is into the body, the other you have to hit and drill to the bottom of a small passage, if you go to deep you have to buy a different steering box.

feel free to ask any questions about it.

[Mud Dog]

Thanks for the explanation Mark, appreciated. I now understand the principles (I could make most of it out before) and how you did it. Interesting modification

[missouriman]

sifu,
so have you been out playing?
any wheeling trips?

[Mud Dog]

Errr ..... Mark, he's been awfully quiet ..... I think he's been out playing and not even back yet! .... Maybe he's enjoying it too much or maybe he's crawling so slow that he's still only ½ way through the obstacle course!

[pietpetoors]

Hi Andrew, thanks for sharing the procedure. Yet again a brilliant and well illustrated article.
I added it to
http://www.hilux4x4.co.za/dual-transfer-case-hilux/for easier reading for those who are interested in it.
There are so many photographs that I had to spread it over 4 pages.