DIY Electric to "Manual" transfer case conversion mod

[Rockit5]

Very cool idea.

How do you know when to stop the shift process? The drill is basically just moving shift forks...is there a detent to make sure each range or mode is fully engaged? That way you're not halfway in or out or pushed too far where you're applying pressure to the slider rings and wearing out those or the shift forks where they'd normally be free floating once a gear is engaged?

From my initial observations while I was messing with the transfer case, is that it really really wants to snap into 2WD and 4LO. 4HI has no detent built in per say. I'm reasonably confident that the transfer case snapping into 2WD or 4LO and hitting some kind of hard stop is by design, but I could be wrong. The hard stop could very well be a shift fork smacking into the side of a gear and I could be trashing my transfer case, I dunno. I haven't torn apart the transfer case yet to see if there's any concern, but I'm all ears from someone who knows more than I do. If I need to make a design change, I already have plans to have some kind of detent to lock the knob in place, exactly like the Shiftster had.

 

[Rockit5]

Any chance you can post the file? I'll print t one up... I'd get it from reddit, but uh... permanently banned

I will once I finalize the design. I'm close, just need to make a few tweaks to the main body, and design a knob and indicator that mounts to the outside of the frame.

 

[pjtoledo]

the rotating rod does not directly more the shift forks. it puts pressure on a spring, which puts pressure on a cam, which puts pressure on the shift forks.
when the gears align that allows the shift forks to move as a result of the spring pressure.
in summation, turning the rod too hard/far won't force damage to anything.

 

[scotts90ranger]

I know there's detents for 4lo and 2hi, when I had that '91 Explorer the E case module didn't work so I just pulled the shift motor and used pliers to go between the two... was enough for what I did at the time... this would be handier and adding the two more detents for neutral and 4hi...

 

[Rockit5]

I know there's detents for 4lo and 2hi, when I had that '91 Explorer the E case module didn't work so I just pulled the shift motor and used pliers to go between the two... was enough for what I did at the time... this would be handier and adding the two more detents for neutral and 4hi...

I think I'll start off with a dummy knob. One with no detents or indicators and just lets you turn from 2HI to 4LO. If there's enough interest I'll make a version with a detent for 4HI. I've heard neutral is kinda tricky because there's only a very small window in the cam where nothing is engaged. a little bit to either side and you start engaging, but very poorly, into 4HI or 4LO and making very expensive noises.

 

[alwaysFlOoReD]

I made my own neutral detente in a Shifster. Iirc it was exactly half way between 4hi and 4lo.

 

[Uncle Gump]

I bought two used Shiftsters over the past year and a half... Just dumb luck in finding them. Sold one to a member and kept the other for my trail tool box.

Looks like neutral was added to this one and I haven't verified it. Seems like I remember the fella I got it from said it came that way from Shiftster.

photo for reference...

 

[lil_Blue_Ford]

Having a way to get to neutral would be nice for repair work and towing the rig.

 

[Uncle Gump]

The one I sold... wasn't indexed for Neutral.

By making a bracket that mounts to the frame... seems the intent is for it to be permanent. That may work well for some... but I'm too old to want to do that as normal operation.

If it's for trail repairs... no bracket needed. Just an indexed knob.

A bracket/fixture through the floor inside the cab... if the flexible extension could be routed to work... would be... IMHO... amazing.

 

[alwaysFlOoReD]

Only pic I could find of mine. Post 62 of my off-road low buck race truck.

@PetroleumJunkie412
I went under my truck to take a pic and it's gone. I can't remember taking it off. Maybe I sold it? If I find it I'll let you know.

 

[PetroleumJunkie412]

Only pic I could find of mine. Post 62 of my off-road low buck race truck.

@PetroleumJunkie412
I went under my truck to take a pic and it's gone. I can't remember taking it off. Maybe I sold it? If I find it I'll let you know. View attachment 144031

Well shit.