Ok, maybe I am over engineering this a bit but I have a wild idea inside of my head at the moment. I am contemplating building a stiffening plate for my transfer case in the hope of reducing the flexing of the stock case. From what I can determine, the internals of the transfer case are capable of handling more power, it is the flexing of the case under loads that is causing the bearings and whatnot to eat themselves.

So, what I am looking for is either pictures or a detailed explanation of where the case is cracking. From there, I can figure out which way the case is flexing and therefore put in the necessary reinforcements. Might even allow me to add a more permanent scoop for forcing air up and around the transfer case to aide in cooling.

I know the 04+ transfer cases are completely different than the 02-03 transfer cases. Seeing how much room an 04+ transfer case has for accessing the drain plug compared to my 03 case is amazing. So, I know that Jag did a lot of re-designing for the transfer case. I'm just not looking to install the 04+ transfer case to gain a little bit of strength. I would like to build something that I could put say 300+ hp to the ground and not have to think twice about whether my car can handle it or not.

 

sounds like a good plan but its gonna be hard to accomplish, good luck. if u do it keep me informed

 

Hope this helps some. This individual had actually lost a bolt and then this happened.

csi190a : well its out and its nasty ,, check your t/c bolts make sure they are all there , 1 missing and this is what happened , not a bad job email me if you need some hints and tips

http://forums.roadfly.com/forums/jag...9008851-5.html

 

Thermo I surely hope you're on to something here. I know I'd like to have a stronger transfer case so I can actually get more power out of my car.

 

i second that..
please do!

 

It would only be flexing in one direction, eh?

 

Not sure how you plan on welding a brace on it or not, but the aluminum is too thin and the internals are just as week.

My other option was to install something from another AWD car, aka Subaru or Mazda. Mazda seem to have a closer fit...but i never got around to check to see how close they were...

300hp is attainable, but I never did a standing launch..maybe that's way my transfer case lasted....

 

Perhaps something more of a strap type support. Would have to be pretty tight. I'd be afraid a rigid weld wouldn't last and you'd feel it in the car. Something more like a crossmember.....

 

I'm thinking it'll be easier to take one out of an 05-06.....

 

I have owned an 03 and now have an 05. I feel hat the 03 was much better in the snow. What was changed from 03 to 05?

 

the viscous coupling. there is none on the 04's and up

 

What effect not having the viscous coupling have on the car compared to one with it?
What, did Jaguar put in place of that, if anything?

 

I have noticed a big difference from my 03 to the 05. The 03 was very sure footed in the snow. Like a tank! When I am driving the 05, I can easily make the rear end swing out when taking sharp corners in the snow. It almost feels like there is little or no AWD at all. I would love to know more about this issue, I don't think this has ever been talked about in detail on this site..... it least I have never seen it.

 

My thought process at the moment is since the case comes in 2 halves, is to build a vertical section that would match up to the bolts holding the two halves together. This would give me a few mounting points across the transfer case (just have to upgrade to some slightly longer and strong bolts for this). This will help in the vertical flexing. From there, using some 1/4" plate, build a piece that would be welded to the vertical piece I added to help in the horizontal flexing. Granted, need to get back under to find some other mounting points at say the rear of the transfer case to help stiffen up the tail shaft section. I don't plan on welding anything to the case directly. welding of aluminum isn't the easiest of things to do and the amount of material needed to get what I think would be the needed stiffness would make the case very large. I am also looking to find some attachment points say on the engine block or transmission to give myself some more leverage against flexing too. haven't looked a lot into this as I need to know the direction of forces.

Christo, as for the direction of forces, you have the input shaft coming in from the side (going side to side in the car), and the rear driveshaft coming straight out the back (front to back). There is atleast 4 possible directions of force.

 

Interesting concept Thermo. I can visualize what you are putting forth. Now, in that pic posted in the thread, was that of the rear end of the TC?

I suppose it would be beneficial to know the direction or location of most of the failures and beef up accordingly.

I would think beefing up the tail end would be somewhat straightforward to prevent twist. Crossmember with bushing would give incremental support in flex.

I think we need some MSPaint drawings...lol......

 

The viscous transfercase automatically transfered power via the viscous coupler between front and rear axles. The non-viscous transfercase does not do this and if I remember correctly the rear axle is the primary drive in non viscous equiped cars. If you have a non-viscous car that doesn't have dynamic stability control it will be as if you have 2 wheel drive in slippery/snowy conditions. If you have dynamic stability control the ABS/DSC system handles the transfer of power between wheels and the difference between viscous and non-viscous isn't normally noticable on DSC cars while without DSC the car will feel as if it is 2 wheel drive.

 

wtf! so since i do not have DSC i more or less have rear wheel drive? Damn i wonder if i can just remove the TC all together so i won't have to worry about it blowing up?