So after converting my auto Jimny to manual I was stuck will its low ratios and high revs on the freeway, wasn't really a problem with the original motor and I wasn't doing many highway k's, now with the new turbo 1.8 things are getting a little hot under the hood as the turbo is constantly spooling at 4200rpm @ 100kmh, the other problem is that getting the electric transfer working with my after market Ecu is proving a pain in the a$$
What I'll be doing then- 1st being replacing the thermostats with a 70deg high flow unit, 2nd changing to a bigger T28 turbo off a 200sx, and 3rd change to manual hubs and transfer and 4th want to change ratios, which is where this thread comes in.
My transfer (from behind the auto) is 1.3 to 1, as are all the manual 'stick' type transfers I could find at wreckers, but the late model electric transfers (from behind manuals) are 1 to 1 which would suit me perfect.
The idea was to change the gears from the late model electric transfer into the early model 2 case, leaving me with great gearing and manual stick type.
I had an old rusted solid stick type transfer laying behind the house so I cracked it open first and checked out how the look and work, then I cracked open the electric 1 - 1 ratio transfer. The main shafts are pretty similar though the gear clusters are pretty different, the selectors in the early boy are steel and the late transfers are ally, the selector shafts are in totally different spots to, also the chain the drives them is about a quarter wider again in the late model transfer.
If the gears where pulled out of the late model transfer and machined down they could probably be placed in the early model transfer but I wanted to keep the wider late model chain.
This photo shows the gear width difference (late model main shaft gear on left and early model input gear on right)
This shows the chain width difference
So if anyone has seen one of these late model electric transfers out you will have noticed a blank in the casting where a shifter could go
You can also see the breather that I tapped into the housing
So far I've drilled and tapped the holes, hole sawed and cleaned up the inside where the spring and pivot sit and dug a ditch round the outside where the selector boot will need to sit.
(the plate is loose in this photo, is why it's not lining up with the 3rd hole properly)
Need to drill, tap and place a small grub screw in this hole which looks to only be there to let water run out of the blanked off casting
Need to sort a few things yet
1- reassemble and see where the selector shaft is in regards to the new shifter hole
2- modify selector shaft
3- modify shifter
4- make 'indents' in the selector shaft and make a locking mech to lock into each gear
5- find a way to stop the shaft rotating as it moves forward and backwards