Zuk on 38's

[Tan Zuk]

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.

 

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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.

 

[Tan Zuk]

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.

 

[Tan Zuk]

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

 

[Tan Zuk]

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

 

[Tan Zuk]

Living in South Florida and trying to get any work done in the shop is a real challenge in the summer. Had to get the shop ready for the approaching Isaac storm. That meant the transfer case needed to be reassembled with the new 6.1 gears. Next on the list was to commence to cleaning and organizing the shop and covering everything.

Unfortunate the last go around worth the hurricanes the tar flat roof blew off the shop and had a river coming thought the expansion joints in the roof. Learned my lesson with that one to get the shop all sorted out and to cover everything up.

Updates no pics this time:

Buttoned up the transfer case

Machined the Zor snatch on the passenger mount a little deeper to get it to swing lower to make the intermediate shaft easier to install. Always have to struggle with this problem with the one on the DD when the intermediate needs to be removed.

Beefing up the stock transfer case mounts that are on the frame with ¼” plate.

Looking at fabbing up an e-brake for the transfer case. Going to pickup a disk from Sky’s kit and use a Wilwood spot caliper for the brake. Will make up a bracket for the E-brake and attach it to the Zor snatch to make it a 17 bolt mount.

Looking at making a rear bumper.

Ordered some front Rubicon YJ’s because I used rears on the front and the added plating to the frame seems to be a bit heavy for the rears up front. Found a good place to get them very reasonably priced and free shipping. I will pass on this info once the springs come if anyone is interested.

 

[Tan Zuk]

Back at it!!! It is now around 89*with a little wind blowing instead of the high 90’s and 100% humidity.

Working on repositioning the front spring mounts since there was just a base line measurement used just to get things started. Knew there was going to be an adjustment needed of at least a ¼” at some time. After all the extra add-ons with the PS, AC and extra plating the amount needed will be ½”.

The 1st set of mounts was store bought and didn’t care for them much. These mounts will be cut off and will not be reused. Made some for the back which are much beefier (¼”) wall all on all surfaces. Will match that design for the front mounts.

 

[Tan Zuk]

Also ordering 3 suspensions seats consisting of:
2 non recliner High Back seats for the front
(Never use the recliner in the DD).

1 Low Back single for the (Rear Seat) to be mounted behind the driver side. Entry for the rear seat will be from the rear door and a step added to the rear bumper to help. This should be easier then crawling up on the back tire then to the running board recline the seat to crawl through the Rig to the crap stock back seat. IMO


Just incase any one was wondering:
When I had the interior reupholstered the fabric was close matched to the suspension seats just incase the stock seats (still sucked). The reupholstered seats were installed in the DD about a year ago and they (still suck) so the suspension seats will be a welcome upgrade.

 

[Tan Zuk]

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.

 

[Tan Zuk]

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.