Double Transfer Case Wrapup, Steering Box Mount Fabrication, And A Shift To The Left
It's been a couple of months since we last visited the Phoenix Project, but rest assured that work, and a lot of it, has been done to our forlorn '81 Toyota pickup. It's far from over. Here's what's happened lately.
When we last visited the Phoenix's double-transfer-case buildup, All-Pro Off-Road's Mike Schoffstall had just completed building the "rear case" of a double-transfer-case system. "Rear case" is in quotation marks because as configured, and as pictured, it could function as a stand-alone single transfer case. In this instance, it is indeed the rear case of a double-transfer-case system. Advance Adapters' Trail Tamer 4.7:1 low-range set and heavy-duty low-range housing are already in place here. This time, we'll hit the highlights while the adapter and front case are installed. This will complete the dual-case transfer-case system. | 
The Advance Adapters TX-2 crawler adapter uses two cartridge bearings, and these bearings must be seated in the adapter plate. | 
Mike used a dead-blow mallet and an aluminum bar to begin seating the bearings. |
Both bearings are installed from one side, which means that the first bearing needs to be driven deep into the adapter plate to reach its final position. Mike used an aluminum disc and his trusty dead-blow mallet to coax the bearing farther into the adapter plate. | 
The double-transfer-case system works by mating a complete transfer case (rear case) with the gear-reduction box from a donor 'case. The main output shaft for the rear 'case is shown. | 
Shown here is a custom Advance Adapters coupling shaft that takes the place of the output shaft in the forward 'case. |
There's a spacer that goes between the cartridge bearings in the AA TX-2 adapter. As shown, the first bearing is held in place by a snap ring. Also note the needle bearing in the second main bore of the adapter plate. The needle bearing is included with the TX-2 kit and also needs to be driven into the adapter plate. Since the needle bearing's housing is rather delicate, it should be installed carefully. Mike's experienced hands tapped everything into place sans drama or damage. | 
Next, there's a low-range gear and bearing that go onto the AA shaft. Slide the AA shaft through the TX-2 adapter plate and secure it in place with the snap ring. Pertinent note: Advance Adapters provides complete instructions with its products; we're hitting the highlights here instead of attempting to duplicate the AA instruction sheets. | 
Here's the high/low shift rail. Since the front 'case only shifts between high and low ranges, there's only one shift rail (and attendant shift fork) used in the front 'case. Advance Adapters provides a short length of key stock that gets welded to the shift fork. Once welded into place, this key stock surrounds the shifter's tip and keeps it from drifting out of place. |
With the bearings in place, the gears assembled onto the custom AA coupling shaft, and with the shift fork and rail in place, | 
the front 'case housing can be attached to the TX-2 adapter plate. | 
Be sure to install the four-wheel-drive indicator switch and the drain plugs. You'll need two drain plugs for a dual-case system. |