[esky]

Need a bit of info about the three styles of transfer cases.

I have an 84 1lt LWB with a 4wd light case, and a WT transfer case.
Questions:

The 4wd light cases with handbrake on the back are the same internal shaft sizes as the WT, but with the (almost) gearing of the 1lt standard transfers?

Should this car have come with this case?

I'll check the flange sizes tomorrow, but should the WT case bolt in, both on flanges and mounts?

If the internals let go in a 1lt 4wd case, will either of the others internals fit?

[303zuke]

Yes, the cases "with handbrake and light switch" came in 2 ratios, a lower ratio in the Type 2 and 3 1.0lt Sierra, and a higher ratio in the NT 1.3lt sierra. The same higher gear ratios were also used in the WT but without the handbrake and with a different bolt pattern on the flanges. All these case share major components, just the gear tooth counts are different for the 2 sets of ratios. The Type 1 1.0lt Sierra case, "With handbrake, but without light switch", does not have any interchangeable parts with the later case design, and the flange pattern is the same as the LJ80 Stockman.

If your LWB is 84, it could be either a Type 2 (metal dash with "4wd" light in small display near ignition lock), or a Type 3 (plastic dash same as 1.3 NT, with "4wd" light in Speedo cluster).

The Type 1 t/case ratios are: Hi: 1.590, Lo: 2.558

Type 2/3 1.0 t/case: Hi: 1.580, Lo: 2.511

1.3 NT + WT: Hi: 1.409, Lo: 2.268

The WT case will bolt into your LWB, but you will need the flanges and handbrake off your old case, and bith Hi and Lo gearing will be higher. Some later WT cases did not have the threads tapped in the case to mount the handbrake backing plate

[rogerworkman]

is there reduction gears available for type 2

[303zuke]

Yes, but you will already have the same High ratio of a 4.16 gearset. If you do order a 4.16 gear set, you will only need the idler gear and the Low Range output gear of a 1.3 t/case.

Other reduction gearsets (4.9, 6.4/6.5 and will replace att the gears.

[joeblow]

there are '2' 1.0 litre switch light cases. one will work with 1.3 flanges, the other will not.

to work out which one will work look at the back of the t/case and locate the area where the centre shaft would be. the casting in this spot will be a round dome shape. this can either be switch light or non switch light and will have the flanges that will not work on a 1.3. the one that will work will have a flat casting rather than a dome shaped one.

[rogerworkman]

so all the reduction gears available for the 1.3 transfer cases will fit my 1 litre 4wd switch case

[joeblow]

rogerworkman wrote:

so all the reduction gears available for the 1.3 transfer cases will fit my 1 litre 4wd switch case

.............if the casting is flat at the rear of the case.

[rogerworkman]

ok thanks ill have a look

[303zuke]

joeblow wrote:

rogerworkman wrote:

so all the reduction gears available for the 1.3 transfer cases will fit my 1 litre 4wd switch case

.............if the casting is flat at the rear of the case.

Or it could have a little hump with supporting webs, the same as 1.3 NT and WT cases. This case was introduced as the Type 3.
If it has a big hump, it's the early case that won't take rockhopper (aka 1.3) reduction gears.

[303zuke]

rogerworkman wrote:

so all the reduction gears available for the 1.3 transfer cases will fit my 1 litre 4wd switch case

And if you do order a 4.16 set, tell them it's for a 1.0 Sierra, because you will only need the new idler gear and a Low output gear from a 1.3. The natural assumption in the US is that it's for a 1.3 and they will supply the 1.0 gears to you.

The 4.16 gears were developed in the 80's by using parts from the 2 different ratios. A Hybrid Idler gear was made by cutting two in half and welding the Hi side from a 1.0 to the Lo side of a 1.3, In those days, CNC machines were the preserve of Aerospace Engineers, and welding the two halves together so that they were true, correct length and the weld didn't fail was tricky. CNC machines have become more common these days and robotic TIG welding is able to remove much of the manual labour, but most companies now just sell new-manufactured complete idler gears.

[Highway-Star]

aarrhhh. So with that massive "dome" on the counter shaft the early 1.0L type 1 case must run bearings on the end of the shaft, not needle rollers inside the counter cogs like the LJ and later Sierra cases do. Would this be correct?

[joeblow]

yes 303....the bottom one with the large hemoroid is the ones that are no good for sierra 1.3 flanges, light or no light.

[rogerworkman]

ok thanks very much 4 the info i hav checked out both of my 1 lt transfer cases and they are both the same as the top pic so now i can order som gears and fit them 2 my spare