How to Fit a 4x4 Transfer Case and Doubler: A Step-by-Step Guide

The process of fitting a 4x4 transfer case and doubler involves several steps, from preparation to final assembly. The first step is to prepare the vehicle for the new components. This includes ensuring that all necessary clearances are made and that any existing components are removed or reconfigured as needed.

When working with 4x4 systems, it's essential to understand the differences between various drive modes and how they interact with the transfer case and doubler. The original equipment manufacturer's specifications should be consulted to ensure compatibility and optimal performance. In this case, we're discussing a front-wheel-drive-to-rear-wheel-drive conversion, where the transfer case is being fitted to a new frame.

The first step in fitting the transfer case is to mark its position on the frame. This requires precise measurements and planning to ensure proper alignment and clearance. The next step is to weld the transfer case into place, using specialized equipment and techniques to secure it firmly.

Once the transfer case is in position, attention turns to the doubler, a component that enables high-range gearing for improved traction and control. The doubler should be fitted according to the manufacturer's specifications, taking care to align its components properly and ensure smooth operation.

As part of the assembly process, several adjustments are made to optimize performance and safety. These include fine-tuning the Ackerman angle, which affects steering response, and making any necessary modifications to improve traction and control.

The final stage involves bolting the transfer case and doubler into place using specialized fasteners and adhesives. This requires careful attention to detail and a thorough understanding of the assembly process to ensure that all components are properly secured and aligned.

Once the transfer case and doubler are assembled, it's essential to test their operation and performance. This may involve towing or driving the vehicle to simulate real-world conditions, allowing for adjustments to be made as needed.

Steering: Hydraulic vs. Pneumatic

When it comes to steering systems, there are two primary options: hydraulic and pneumatic. Both have their advantages and disadvantages, and the choice ultimately depends on personal preference, budget, and specific requirements.

Hydraulic steering uses fluid pressure to actuate the steering system, providing precise control and responsiveness. However, this method requires a significant amount of power and energy, which can be a drawback in certain situations. On the other hand, pneumatic steering relies on compressed air or gas to operate, offering a lighter and more efficient solution.

In this particular project, we've opted for a pneumatic steering system, utilizing compressed air to actuate the steering components. This choice allows for greater flexibility and control, making it an attractive option for 4x4 enthusiasts.

Transfer Case and Doubler Details

The transfer case is a critical component in 4x4 systems, responsible for transmitting power between the front and rear axles. In this project, we're fitting a new transfer case to replace the original, with the goal of improving performance and capabilities.

The doubler, on the other hand, enables high-range gearing for improved traction and control. This component is essential for navigating challenging terrain, and its proper installation is crucial for ensuring safe and reliable operation.

Engine and Drivetrain Installation

Once the transfer case and doubler are assembled, attention turns to installing the engine and drivetrain components. This requires careful planning and execution, as each component must be properly aligned and secured to ensure smooth operation.

The transmission is a critical component in this project, providing the necessary gearing for optimal performance. In this case, we're using a custom-built transmission that offers improved capabilities and control.

Frame and Chassis Modifications

Throughout the assembly process, several modifications are made to the frame and chassis to accommodate the new components. These may include cutting or welding to achieve proper clearances and alignment, as well as installing specialized fasteners and adhesives to secure everything in place.

The final stage of the project involves completing any remaining details, including bolting the engine and drivetrain into position. This requires careful attention to detail and a thorough understanding of the assembly process to ensure that all components are properly secured and aligned.

Conclusion

Fitting a 4x4 transfer case and doubler is a complex and challenging task that requires patience, skill, and attention to detail. By following these steps and taking the time to understand the underlying principles and mechanisms, enthusiasts can create a reliable and capable 4x4 system that meets their needs and exceeds expectations.

Throughout this project, we've covered the essential components, assembly process, and adjustments required to optimize performance and safety. We've also explored the options for steering systems, transfer case and doubler details, engine and drivetrain installation, and frame and chassis modifications. With these insights and guidance, you're ready to tackle your own 4x4 project with confidence.

The final result of this project is a robust and reliable 4x4 system that's capable of handling challenging terrain. The transfer case and doubler are securely bolted into place, providing smooth operation and optimal performance. The steering system responds precisely to the driver's input, while the engine and drivetrain work in harmony to deliver exceptional capabilities.

With this project complete, you've demonstrated your skills and knowledge as a 4x4 enthusiast. You're now equipped with the tools and expertise necessary to tackle even more ambitious projects, pushing the limits of what's possible in off-road driving and adventure.

"WEBVTTKind: captionsLanguage: enforeign welcome to another day of working in the shop today we are not working on the heavy wrecker because we're waiting on parts for some of the drivetrain but that's great because Lizzy broke the banana yesterday I didn't break it it broke itself so we have a maintenance day that we should take plus it's been forced upon us so that's what we're working on today we're replacing the U-joint on the passenger tire you joint and axles she did she done good grab the impact and the Allen wrench and start picking this apart I can hold all of them in my hand so we've got a Dana 60 a super duty axle that we're going to be narrowing because we have narrow track axles on this about 60 62 inches wide anyway that's a pretty big project to make that super duty axle to get it where we need it look for that coming up quickly but until then we just got to keep this 44 alive I got it so let's try the butter you joint all right so I was under the impression that the full width Chevy axles the long side was the same as the narrow track and all the difference was made on the short side that's not the case so an axle an inner axle that I thought would work won't work because it's too long so now the Banana's down you have this axle out of it and we need new axles we gotta find one somewhere so the banana all right so we got shut down on fixing the banana it didn't take as long though but we got other things to do so we're going to bring the off-road trailer in and we're gonna fix the winch situation on that that's like right now the soonest we've ever redone something after we did it did it and then didn't use it and now we're gonna fix it before we use it again so the banana with a bust we're gonna be productive anyway since we don't have parts for the heavy wrecker we're gonna start working on something else so we've got this new winch mounted in the wrong location we did it in haste a couple days ago didn't even end up using it on the job now we're going to mount it forward and a little bit lower what's happening is the side by sides the utvs a lot of them are so big and if they put aftermarket suspension and stuff on them they can only be loaded backwards we're going to permanently mount a battery so we're going to build a battery box and yeah all right foreign let me finish filming this and then I'll call you straps in our on our winch remote and we're also going to do a battery hold down so this doesn't come flying out when we're bouncing down the road okay that's really hot so we're gonna let that cool off so I don't melt a hole in the case while I put the battery back in there I'll put a strap across the top and we'll put some rubber in there and then the battery Mount should be done holes are drilled we can go test fit this and see if it's going to work this piece of metal I'm going to cut out because everything I tried to do to straighten it just made it worse so that's going to go we'll build a little mount in there and just weld these things right in here thank you and now for the moment you've all been waiting for we are back working on the heavy wrecker we're going to be doing drivetrain Parts midnight Metal Works came through the new parts that they want us to put in there they are updated upgraded stainless steel AR Billet all of the fancy words that's what we got oh Lizzy I'm supposed to talk to you about something so Lizzy was fidgeting with a tape measure in a very abusive way two by six typing to go under the record and I didn't see it until you guys saw it and I'm like okay well we have something to say in the morning so Lizzy says she's not gonna do it anymore right no it's trouble all right we are ready to start working on this again and by this I mean that well these guys are getting this all rigged up to get the wrecker pulled back in here Lizzy get your stool get all your welding gear so what we're working on is the bracket for the hydraulic ram steer the wrecker you're gonna tie the knot yeah I'll tie the knot you can do a bowl Line This Time listen I didn't tie a bow line last time and I got in trouble so we're gonna we need a bow line Tom does know knots Tom's an eagle scout too well they're a bowline here we go there's there's our bow line yeah all right so we're gonna be trying this out today I'm curious how that works I know we already showed you that once but we showed you it again because we did it again so Lizzy the first thing I want you to do is put a nice tack there a nice tack there a nice tack there then pull that off and put a nice tack there put attack there and attack there so you just need to pack this in place so this one's gonna be identical to that one okay so what's going on here is this bearing needs to be retained there's nothing to stop it from slipping out except for a slight press fit here which isn't enough to keep all the gear stuck we're gonna weld this on there and that will retain it see if that'll do it okay put a tack on that so let's get those Ram pieces and a straight something straight so this puts the center of this like right there what I don't want to do is hit this under full compression so all I need is six and a half inches right here so move it down an inch and a half yeah let's move it down so let's go down an inch and a half that's about right there six and a half that's it like that's it right there so we've never done this before we're trying to get everything to fit without conflict I'm feeling 99.9 positive that we've got it right so we're gonna start bombing it in now it's good after this foreign I was gonna see if we should take bets on how many were missing but it looks like zero we kept everyone we did that but we did a little bit okay spin it spin it I've been waiting for this oh they're not even moving well make something happen try some shifting see what it does so we're in neutral both of them are in neutral okay go back that's front wheel drive rear neutral that is four wheel drive low range okay hop out in the new fill now your four wheel drive rear okay now I'm front wheel drive to a rear-wheel drive high range okay and now your four wheel drive high range all right it works everything it works so Lizzy got that all welded up and now we're getting ready to fit that all right so that's how that's gonna fit it's still too hot I want to let it cool down a little bit more but it does fit we've got it back as far as possible in the future we're going to be putting shorter arms on here for more steering angle and and a little faster steering ratio on the rear we're gonna leave it like this because we don't need as sharp of turning we don't need as fast as turning and the ackerman's actually right for the rear we're gonna have to fix the Ackerman angle here and the Ackerman angle is like some geometry for steering that keeps the tires from scrubbing as you go around the corner it's really boring what do you think Ed yeah it looks like it's going again okay do I want a skid plate underneath it and I originally designed this because I imagine that this would work now I've got second thoughts so that's what it would look like wow that's a lot of gaps to fill that would be really strong though and I don't know mom is there a better design than this you probably want to cut this corner off or tie it in somehow hand me the Stinger really quick I'm gonna put attack so reach in the other side and put attack on the top do a full pass on here a full pass on here do a root pass on the bottom fill it on the top and the bottom and then a nice pretty one all the way across there okay now we just got to get the shifter rail thing on the back and then this baby is ready to go that looks really good this is the real bumper anyway while Lizzy's over there welding on that we're gonna finish putting this transfer case and doubler together in fact Tom's already started bolting this on yeah the first piece is on so we just got a bolt on the back half and it'll be ready oh that's quite good all right so we've talked about this before but what's Happening Here is this is the transfer case and this is a gearbox in front of the transfer case that gives us more gear options specifically low gear options okay yeah that is this is 5.44 yeah so you should be able to turn this 5.4 times to get one on this one two three four five and that should be it yeah right there okay it works everything's together right should hold up all right we are ready to marry these two things together with this adapter Tom got back from the store he got the bolts we need we're gonna put this together I put anti-seize on any any bolt that's going into aluminum I use aluminum anti-seize I have never regretted it it's ready to bolt to the engine and then it'll be ready to set in yeah yeah we should have it running driving driving soon so we're gonna leave this till tomorrow to bolt it up set it in we're going to move to this we're gonna see if we can get this to steer today with the ram all right you got a plan for that I do okay this is just temporary the only one inch bolt I've got in the shop see if we can get this to turn under its own hydraulic power except for it's going to be pneumatic power I don't have enough pressure we're gonna have to jack it up take a little bit of pressure off of this and then we can steer it because instead of thousands of PSI we have tins I can stop it with hand okay is that all of it all right go back and forth I want to see okay so what do you guys think should we do hydraulic steering or should we do pneumatic steering that is steering with air pressure instead of hydraulic pressure for those of you that sit I don't know what they do for those of you that don't know the back one's done Lizzy says the back one's done let's go look at it yeah this one's ready to set one in all right it's quitting time we got a lot done Tom worked really hard on this the transmission Transportation doubler I feel really good about that Lizzy welded her little heart out today thanks Lizzy it was awesome I love welding thick stuff that big old thick steel just next week we are going to get the engine the drivetrain set in the frame here bolted in we're gonna get the least thought done dissolving little problems and welding and doing all that thanks for watching did we lock titles you built those\n"