Fitting a LT95 transfercase to a 700r4 trans

When I was searching the net for details I got zip on the LT95
Got a few strikes for LT230 one in Aus that had been done but not documented at the end of the build, might have even been this site (memory isn't flash and was a while ago)
Just about all the comments from the American sites went on about how it was impossible due the 700 sump being to wide and not leaving enough room for the drive shaft lol Interesting to find out they were professionally done in Aus

Any chance any of those that still have them could take a pic of the setup

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ID have thought the lt230 would have beena simpler prpositions.

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Lol yes it would have, I even bid on one locally on our version of ebay, but I'm way to cheap to pay over $800 for a transfercase!
I had the LT95's sitting there and they are plenty strong enough for an old V6 commy lol, and at this stage the conversion has cost me $35 for a second hand cutter to cut the spines for the PTO dog clutch lol still have to sort the adapter housing between the case and the trans tho

Sorry was going to post the PTO but got an open home today and getting in trouble for not cleaning lol

I know this isn't the PTO bearing carrier.... but it is what I'm working on at the moment
Joining one shaft to another

I'll start with the transmission shaft, due to this coming from a RWD car (vp Commy) the output shaft is longer than I wanted so I decided to shorten it as much as I could... this has ment cutting a new spline on the shaft

Over the yrs I've worked out an easy (but slow) way of doing this on a minimal budget machine tools wise
I use a cheap Mill/drill and grind them in, here is the trans shaft getting the roughing cuts
https://www.aulro.com/afvb/images/im...014/05/416.jpg

I have made up a tool holder that holds a standard 1mm 5" cutting disk I use these to rough out the splines and another to hold a 6" aluminium oxide disk that is profiled to the shape of the spline using a dressing diamond

Here is a shot of the final shaft next door to a spare shaft that I've done a roughing pass on
https://www.aulro.com/afvb/images/im...014/05/417.jpg

You'll see a collar on the end of it... unfortunately I'm unable to cut female splines (internal) so I cheat and source these from junk parts in this case a drive flange from a blown hilux diff it happened to be 0.2mm smaller than the major dia so all I did was lathe it down after I'd cut the splines
As for indexing I was lucky and the original output spline and the hilux spline were the same count so I just indexed off the original output spline

The LT95 shaft had a couple of issues
https://www.aulro.com/afvb/images/im...014/05/418.jpg

I need to keep the section on the right of the selector gear, the twink pen mark is where the case seal sits so the spline will be to the left of this... that ment to fit the grinding disks the fixed gear had to go
https://www.aulro.com/afvb/images/im...014/05/419.jpg

Next issue is it is a very large shaft.... after trying a car wreckers and a light commercial wreckers without any joy I ended up pulling an old toyota hilux automatic transfercase apart and found a splined selector gear that is only 2mm smaller dia than the shaft as a bonus tho the spline profile is the same as the smaller spline on the trans shaft
https://www.aulro.com/afvb/images/im...014/05/420.jpg

Machined the female spline down to a collar that I can sweat and weld into a machined bit of hollow bar joining both collars
The male spline is hacked out and using the oil gallery in the center of it and the LT95 shaft a piece of machined rod is used to hold the male spline to the shaft while I welded it in place... so I can use this as an index for cutting the splines (tomorrow nights job lol)
https://www.aulro.com/afvb/images/im...014/05/421.jpg

oh and this is on the end of the shaft I'm going to cut off after I have cut the spline

That's impressive.:BigThumb:

Happy Days

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Originally Posted by joel0407

That's impressive.:BigThumb:

Happy Days

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X 2 !

I love to see the problem solving happening in this sort of work.
Keep it coming :)

Steve

Seems you're channeling Wagoo here...what's next, SWB 6x6 with portals and twin transfers, all home made of course?

Well done on your work thus far

Thank you for the comments

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Originally Posted by isuzutoo-eh

Seems you're channeling Wagoo here...what's next, SWB 6x6 with portals and twin transfers, all home made of course?

Well done on your work thus far

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Wagoo? don't know that one
Arghh I'll leave the 6x6 to Bill lol the portals hmmm shame they arn't legal for comp here.... and yes I am collecting parts incase I decide to make some.... twin transfers blaa, try 200 to 1 reduction with twin gearbox's done that lol working on a stronger version with PTO for a winch

Right here is the old LT95 shaft getting the final shaping using the Aluminium Oxide disks.... you can see the shape I have profiled it with
https://www.aulro.com/afvb/images/im...014/05/322.jpg

As you can see its simple mounting nothing fancy needed, even the indexing setup is from the scrap bin lol
and here is the shaft cut down to size with the collar
https://www.aulro.com/afvb/images/im...014/05/323.jpg

Now all I have to do is mount up the transfer case housing and machine a seat for a seal so I can separate the transmission from the transfer case
with that done I sort how I join the cases

this is still a bit up in the air, toying with an adapter that is bolted onto the transfer case from inside it using counter sunk cap screws then bolts to the back of the trans hmmmm

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Wagoo? don't know that one

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LOL just worked it out, Wagoo is Bills user name on this site, built wildthing.... thank you thats a complement

Been working on the "sandwich housing" that joins the two cases, needed a good surface to bolt up to on the Rangie transfer case
https://www.aulro.com/afvb/images/im...014/05/109.jpg

While I was at it I cut the seat for the transfer case input seal
https://www.aulro.com/afvb/images/im...014/05/110.jpg

The end result
https://www.aulro.com/afvb/images/im...014/05/111.jpg

It has two levels I know but I had to machine the lower bit down due to a casting hollow... not good to have a hollow under the bolt thats sposed to clamp the two pieces
With the face ready I made the plate to match, and faced it true on the mill, all the bolts coming through from inside the transfer case are counter sunk or recessed.... that was a bit of fun, as I wasn't able to get a counter sink bit in there so all of them had to be cut in with a die grinder by hand, a real slow process of rough out, high point with blueing ink, cut high points, blue etc till it was close then using a long bolt that I ground a couple of cuts into the head and a drill on the thread pulling it through polish the counter sink
https://www.aulro.com/afvb/images/im...014/05/112.jpg

The trans end was just a case of trim and machine up a bit of 25mm plate
https://www.aulro.com/afvb/images/im...014/05/113.jpg

Now its a case of getting the joiner sheaved and sitting the two cases in line so I can work out how to join the two plates that are bolted up
I also installed the shortened shaft in the trans as you can see from the pic above.... I'm not going to bother with pic's and how I did that... my recommendation is don't go into one of these with out a good manual that is specific to that model trans lol they can be very frustrating to get back together! lol

May get this all joined up this week.... will depend on how hard I have to work on a mates truck to get him to a comp this weekend lol

Nice work.
Im pretty sure when I did mine those years ago I put flat washers under the bolt heads in the T,case to spread the load. I didnt think they were close enough to anything to warrant countersinking.