Topic: tcase choice

[jagular7]

I am at crossroads on choosing which tcase/combo to use. I've got several tcases on the shelf in various conditions and expected working capabilities right now. I'm looking at using my Klune with a 205 in my TJ for better offroad crawling abilities. I'm planning a flat belly and wanting to do the tcase/doubler while I'm at it. My tcase choices are Ford EB D20, Jeep CJ D300, Klune (2.72, setup for C6/205 Bronco project), Jeep TJ 231 w/SYE, Ford truck 203, and Ford truck 205. The Klune was purchased back in 02 and never installed (Bronco project that has been sitting that long!!!). Ford 205 was rebuilt back then and ready to use.

Bronco project - nonrunning, needs D60 front axle, 4.10/Detroit front, front suspension, and 460/C6 installed, have 203 for double setup with the rebuilt 205, etc, etc. needs more work, money, and time.



TJ project - running, 4cyl/auto, stock driveline, has 3" suspension, 1" body lift, bumpers, winch, 4.88s, locked front/rear, etc. needs better crawling ratio, needs flat belly.



Ford Dana20 - unknown working condition, needs internal cleaning, possible rear ouput hi-gear as the leading edges are rounded, needs shifter(s) for twin sticks, has cv yokes, 2.46 low gear, twin-stickable, 3.15 low ratio available (~$650), 32-spline outputs available, possible trans interference (auto trans on TJ). Minimal needs rebuild. Use with Klune requires Klune adapter, Jeep auto input shaft for ~$500.

Jeep D300 - came out of running vehicle, good working condition, 2.64 low ratio, twin-stickable, flip kit required (2 costs I know of cheapest is under $200), 4.0 low ratio available (~$600), need cv yokes, 32-spline outputs available. Use with Klune requires Klune adapter, Jeep auto input shaft for ~$500.

Klune - purchased back in 02 for the Bronco project. Downtime, I purchased TJ, bolted on upgrades, back to school, other vehicle purchases/projects put the Bronco work on stand still. 2.72 low ratio, setup for use on C6 and 205 for doubler. Still brand new never installed.
Ford 205 - rebuilt back in 02. Ready to be used. 1.96 low ratio. Setup for twin sticks. Front cv yoke, 1350 rear yoke.
Jeep TJ 231 - needs pump/bearing. Purchased recently in bad working condition. AA shaft. CV yokes.

I still have my original 231 to work with. I was looking at using the Klune for the TJ and 203 for the Bronco. I wanted to keep the 205 for the Bronco. However, there are other incidental costs associated with the tcase swap - front/rear ds mods/new, cv yokes, ujoints, shifters, and mounting. So if I keep it low costs and to get the TJ on the road quickly for wheeling, I can use the Kune/205 on the back of the TJ auto with a $175 cost to get the Klune a 23-spline input to mate to the TJ auto trans. However, doubling the Klune 2.72 with the 205's 1.96 isn't much of an increase in crawlability. I haven't cost the 4:1 for the Klune just yet, but will Monday. The other cases have greater potential with lower gears, but I can always swap cases later also once I get the Bronco closer to running condition.

What do you all think?



Oh, I forgot about my Bronco's 1356 as any option. It has cv front with rear flange output yokes. Similarly designed like the NP231 except the pump is on the output shaft and is held from spinning by a tab and interal case recess. It has over 215k miles on it if its original.

[Jeffy]

Klune/D20 for sure.  That's a small package and is tough.  Not to mention, has the right output for your current axle.  Although it would have been better to have the 4:1 'David' although you might not need that low of gears where you are.  6.7:1 ain't bad either but it does give you a lot of gear overlap.  There used to be really low gears for the D20 years ago.  I think something in the 4 range but I don't see them anymore.  All there seems to be are 3.15:1's.

You could do the Klune/231 though too.  You'd want to have the 1.25" chain and sprocket set installed as well as a HD output shaft.  If you were going to do a 4:1, it would add a lot more, making the D20 look cheap.

Other option would be to sell the Goliath and buy the David.  Then you won't have to be installing lower gears into the transfer cases and still have lower gears overall.  Not to mention cheaper as well since the David and Goliath cost the same, IIRC.

[oldjeep]

Personally I'd sell the Klune and a bunch of those other tcases and get a STAK case.  The klune should be OK, but I've seen them break behind a stock 4.0L.  There is almost no way that it would survive behind a 460, a 203/205 would be a good combo for that setup.

[Bounty Hunter]

Not all t-case setups will clock up flat for a belly-up skid, and not all are short enough to use in the TJ.  You wouldn't have much rear driveshaft left when using the Klune in front of the 231, I've seen it done but the engine was moved forward at least the length of the Klune.

For ease of installation and cost factor, I'd consider a Tera 4:1 in the 231 or a 231/300 doubler.  Both are short and can clock considerably flat, with the 231/300 giving you more gearing options than the Tera 4:1.