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Unread 09-28-2011, 01:44 PM   #1
MrPoot
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Dual TC setups

Howdy yall. I'm in the process of sourcing out parts for my new driveline and I'd like to know what transfer case setups people have had success with. In front of the TC I'll be running a wide ratio ZF 5 speed transmission (5.7 granny first) and a cummins 4BT motor. I'd like to have a dual case setup without doing a rear end stretch. Anybody done that on here?

I know there are underdrive setups like the klune or blackbox that would most likely fit, but I'd rather not fork out that much cash at the moment. Don't really wanna buy an Atlas either.

Here's a few setups I've come across, I just don't know if they will fit:

203/205 doubler, 203/d300 doubler, 241/241 doubler, 231/231 doubler, 241/231 doubler.

I think the shortest ones are the 203/205 and 203/d300 (with flip). Are there any other options out there that I am unaware of? If not, which is better between the 205 and d300? I know the d300 is more upgradable, but the ford 205 has larger splines. Any thoughts would be much appreciated!

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Unread 09-28-2011, 02:26 PM   #2
dillonjm
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I really doubt you're going to have room to do a double t-case without a rear stretch, the rear driveline is pretty short with only one.

I'd think you'd have to shift the motor pretty far forward on the frame to even have a shot at this working which would pretty much screw up your tranny placement.
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Unread 09-28-2011, 03:53 PM   #3
timatoe
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Quote:
Originally Posted by dillonjm View Post
I really doubt you're going to have room to do a double t-case without a rear stretch, the rear driveline is pretty short with only one.

I'd think you'd have to shift the motor pretty far forward on the frame to even have a shot at this working which would pretty much screw up your tranny placement.
I agree, with the stock drivetrain and a 8.8 SOA, my rear shaft is only 18.5" long at rest.
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Unread 09-28-2011, 04:18 PM   #4
hesserdude07
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x3 on agree. I have a 350/700r4/hybrid 231 and i also am stretched. And my rear shaft with the short SYE is only 20" long... I would bet you'd lose atleast 5" with the doubler
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Unread 09-28-2011, 05:43 PM   #5
MrPoot
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Correct mr if im wrong, but i believe a 203/205 doubler is 17.5 in long. Stock 231 is 18.5 in. Granted my 231 is shorter now with the super short sye. So im only looking at a change in length of +- 2 in.

Also, i think (havent picked up the new zf) the zf 5 speed is shorter than an ax5.

With that said, i know a d300 isnt too far off in size wise to a 205, but the d300 has lower gearing, and can be upgraded to 4-1 later on if i wish.

Any thoughts?
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Unread 09-28-2011, 06:23 PM   #6
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The 231 can be upgraded to 4:1. Look at mine! If you want super low gears go with an atlas. You can get reduction down to 10:1 and it's gear driven and not chain driven. With more horsepower comes greater risk for breakage. Keep your driveshaft long and your transfer case where it's supposed to be.
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Unread 09-29-2011, 02:56 AM   #7
yjgrillin
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I'm not positive but when I was looking at upgrading my tcase, I thought I saw that a d300/231 doubler is only a couple inches longer than stock. I'm sure someone can chime in and correct me. Haven't done it or looked that much into it, so I don't know.
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Unread 06-29-2013, 02:25 PM   #8
MrPoot
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For an update to an old thread, I did indeed do a dual case setup. My drivetrain is currently Cummins 4BT - NV4500 - NWF Blackbox - Early bronco D20.

Never had to stretch the wheelbase. My rear driveshaft is about 18 in long. No vibration issues at all.
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