Revolution Gear 3:1 install ('99 Trooper manual)

Discuss anything related to drivetrain mods here (Engine &Transmission Swaps, lift, gearing, exhaust, etc)

Moderator: Staff

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sat Apr 17, 2021 7:30 pm

I drained the fluid and there are some long strips of metal. I'm thinking a snap ring got torn up. If so, that might explain the extra lash.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Sponsor
 

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sun Apr 18, 2021 3:37 pm

Image
Image
Image

Case is being pulled and cracked open today to find out what's going on. Plenty of glitter in the oil that was drained. Hope it didn't chew up the gears too bad. Glad I have a spare case and gear set sitting around I guess.
Last edited by Enemigo on Wed Apr 21, 2021 2:13 am, edited 1 time in total.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby lorenzo816 » Sun Apr 18, 2021 3:40 pm

Snap ring for the synchro. My best guess because you had the dog teeth backwards.
Inertia shot it out.
Or snap ring for one of the bearings.
Hope teeth are okay.
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float :: Chromoly Bling Bling
Build: 3-link coilover front 44 & rear FZJ80 on 37's
PM me if you need anything - Need a Skull Planet Isuzoo sticker?
User avatar
lorenzo816
I am the Stig
 
Posts: 3822
Joined: Wed Jul 19, 2006 2:36 pm
Location: North Carolina
Has thanked: 120 times
Have thanks: 137 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sun Apr 18, 2021 5:45 pm

Here is the only damage I can see so far.
Image
Image

The interference, and the noise, is coming from these teeth making contact. This is on the gear where the dog teeth are I guess installed backwards. I'm going to go back through the thread to see what Lorenzo posted to verify. When I shift it into 4wd, the teeth don't hit, and depending on how I orient the case, the noise goes away as well.
Image

There is still the issue of where those long metal strips came from. I've got that other gear in the other transfer case as well. Even though that one chip doesn't really bother me, I'm going to pull this gear from the other case to verify how the teeth sit. Also it will give me a chance to figure out the most efficient way to get this out on the case that counts.
Last edited by Enemigo on Wed Apr 21, 2021 2:14 am, edited 1 time in total.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sun Apr 18, 2021 5:47 pm

lorenzo816 wrote:I hope everything shifts smoothly. Looks pretty good to me except the synchro 'dog teeth' and I'm going to have to verify on a case once I get another one apart.
The book and my memory remember this as the orientation. If anyone has done a synchro gear on a NP case before, they are set the same way.
synchro.PNG


Looks like I've got them in backward, and those snap rings are probably what go blown out, just like Lorenzo suggested. Let's see if I can get it all back together and driving today!
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby lorenzo816 » Sun Apr 18, 2021 7:03 pm

Strips are the snap rings most likely.
Go back and read through what I posted on the last one I did and you’ll be set.
Use that pick you have or something thinner stronger like a dental pick.
Now for the 4wd cluster, if the other is same count is just swap it for piece of mind.
That might cause skipping in 4wd but not positive - that would depend on how deep the chip is.
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float :: Chromoly Bling Bling
Build: 3-link coilover front 44 & rear FZJ80 on 37's
PM me if you need anything - Need a Skull Planet Isuzoo sticker?
User avatar
lorenzo816
I am the Stig
 
Posts: 3822
Joined: Wed Jul 19, 2006 2:36 pm
Location: North Carolina
Has thanked: 120 times
Have thanks: 137 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sun Apr 18, 2021 7:18 pm

I'm working on just swapping the 4wd shaft all together. I still can't even see this snap rings, so might as well just take the assembled shaft and swap.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby lorenzo816 » Sun Apr 18, 2021 8:35 pm

I’m thinking that you now don’t have a Synchro also on the main shaft hub gear.
Which is good news that you don’t have to do a full disassembly. I was thinking this was on the main shaft but since this is on the four-wheel-drive cluster, then you can just partially disassemble and swap the whole unit trying to keep collar in place so that the dog teeth don’t spring out of the replacement.
1997 Solid Axle Rodeo :: Ar5 swap :: Revo 4Lo :: 5.29/5.36 :: Front OX :: Rear ARB :: Full Float :: Chromoly Bling Bling
Build: 3-link coilover front 44 & rear FZJ80 on 37's
PM me if you need anything - Need a Skull Planet Isuzoo sticker?
User avatar
lorenzo816
I am the Stig
 
Posts: 3822
Joined: Wed Jul 19, 2006 2:36 pm
Location: North Carolina
Has thanked: 120 times
Have thanks: 137 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Sun Apr 18, 2021 9:19 pm

Yeah that's what happened. Just trying to get that center sorting clip back into place now.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Re: Revolution Gear 3:1 install ('99 Trooper manual)

Postby Enemigo » Tue Apr 20, 2021 12:28 am

I was so excited to be out test driving the Trooper that I forgot to update. I was able to pull the transfer case out of the vehicle, separate the halves, pull the 4wd shaft out, and replace with the undamaged 4wd shaft from the donor case, then button it back up and reinstall. All in a single day, which is a miracle for me. I'm sloooow when I work on stuff.

Anyway, everything seems to be working and no other damage was found inside the case. I did a test drive today, but haven't tested the low range again yet. I really liked what I felt when I tested it right before it broke though. I would consider this mod a success. I love the change the low gears provide. Now I'm hoping to be able to use less gas pedal on obstacles and give me more control. I wasn't sure how it would feel going from 2:1 to only 3:1, but it is a very noticeable difference. I can't imagine a Rubicon with 4.10:1, or my buddy's 4Runner with 4.7:1. The nice thing about these 3:1 is that most of my off road driving occurs during hunting, and 4:1 would be too low. In fact, the 3:1 might even feel too low for cruising fire roads. Thanks for the help of everyone that contributed to this build. It may not be the best how-to, but I'm glad that we finally have one.
1999 Amigo - Sold
1999 Trooper. Mods TBD
Enemigo
Zu Royalty
 
Posts: 1046
Joined: Thu Jun 30, 2011 11:41 pm
Location: Colorado metro area
Has thanked: 4 times
Have thanks: 25 times

Previous

Who is online

Users browsing this forum: No registered users and 3 guests