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URGENT HELP - Rebuild manual transfer case with auto internals

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  • Jamiec
    Junior Member
    • Apr 2019
    • 7
    • Auckland

    URGENT HELP - Rebuild manual transfer case with auto internals

    Hi all
    Sorry to spam.

    Ongoing transfer case issues

    3500 Petrol Manual V25

    1st replacement transfer case supplied, turned out to be auto (560 length) (Same as current)

    2nd supplied is manual but much shorter than it should be (490 length)

    Looking to rebuild my case with the auto internals (Chain has snapped)

    I read somewhere that this can be done. Someone please confirm for me

    Truck is pre sold, awaiting pickup tomorrow. Currently sitting in the mechanic in pieces
    Attached Files
  • erad
    Valued Member
    • Mar 2015
    • 5064
    • Cooma NSW

    #2
    This isn't of much direct help to you, but my dim recollections tell me that the manual transfer box had a neutral position on the lever, whilst the auto did not - it went directly from 2H to 4H with no stop in between.

    Comment

    • Dongskie2
      Member
      • Dec 2016
      • 170
      • Manila & Berwick

      #3
      Does it matter if it's the 2.5 diesel?

      Auto, 2H to 4H directly.
      Attached Files
      Nothing beats Doing It Yourself.... Tuned 4M40 and 4D56T WIP

      Comment

      • Jamiec
        Junior Member
        • Apr 2019
        • 7
        • Auckland

        #4
        I read only the 2.8td and 3.5 petrol are the same

        Proceeding to try build one out of 3 but spine counts are all different

        Hopefully just replace parts in the rear half of the box provided rear spines are same count and leave the main internals....

        Will let you know the outcome

        Comment

        • Jamiec
          Junior Member
          • Apr 2019
          • 7
          • Auckland

          #5
          So to follow through with an answer..

          2.8TD and 3.5 Petrol transfer cases are the same. Referred to as the 'big box'

          Auto internals can be sacrificed to rebuild a manual case

          Comment

          • nj swb
            Resident
            • Jun 2007
            • 7327
            • Adelaide

            #6
            Originally posted by Jamiec View Post
            So to follow through with an answer..

            2.8TD and 3.5 Petrol transfer cases are the same. Referred to as the 'big box'

            Auto internals can be sacrificed to rebuild a manual case
            Good to know. Thanks for updating.
            NT Platinum. DiD Auto with 265/70R17 ST Maxx, Lift, Lockers, Lockup Mate, Low range reduction, LRA Aux tank, bull bar, winch, lots of touring stuff. Flappy paddles. MMCS is gone!

            Project: NJ SWB. 285/75R16 ST Maxx, 2" OME suspension, 2" body lift, ARB 110, 120l tank, bullbar, scratches, no major dents. Fully engineered in SA. NW DiD & auto in place - a long way to go....

            Scorpro Explorer Box

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