anyone ever put a divorced 205 in a sami ?

[wasted wages]

helping my friend build up a project rig....

Divorced Zuki transfer case literately fell out.....broken mounts and ears busted off the case itself....

Was thinking of using a divorced 205 to replace it and fabbing up a crossmember to hold it.....

overkill ????

 

[blazinzuk]

yes and dumb. One of a samis huge advantages is its light weight. Was he using aftermarket mounts , stock rubber or solid. Different motor? Different axles?

Sami t cases arr pretty good but they need to have solid mounts and a couple more attachment points on the t case

 

[n4xplay]

If he still planes to use the stock motor then replace the transfer case and repair the mounts. if he is planning to put a v6 or v8 in it then that’s a different story, samurais transfer cases are not 1:1 in high range so if this is a daily driver than its best to stick with stock. And get a transfer case cradle from trail tough or zuks off road (ZOR) and it will live longer.

If you can tell us what your friend intends to do with it offroad and future planes I may be able to help more!

 

[Ned Kelly]

I agree, stay with the Samurai tc. NP205 is silly for this applicaton. Beef up the tc cradle. Several good options are available.
http://www.lowrangeoffroad.com/inde...ai-eos-extreme-duty-transfer-case-cradle.html

 

[wasted wages]

Its strictly an off road toy....all stock axles ( lower gears than stock) 32's
has a small lift....

I haven't seen the damage to the case yet since he pulled it out...
but I did see it flopping around under the truck while we loaded it on the trailer.

It may be fixable .... I don't know yet.. I don't know much about sami's,,,are the t-cases expensive ???

It's just a tiny damn thing....

 

[n4xplay]

Search ebay you may be able to find a core or the case
Halves for around 200

 

[Stomis]

If your sticking with a 1.3 or 1.6 you'll want that lower hi range gearing a zuk case offers. If you have plans on re-powering it to something better Id look into a divorced toy case kit. Or just say F it and buy a $500 crappy toyota and put a 22re/w56/toy gear case in it.

 

[n4xplay]

for the long side repair you can pick this up
http://www.zuksoffroad.com/Panty-Liner-driver-side-t-case-mount-reinforcement_p_70.html

there cradle is awsom as well

the toyota drive train is perfeckt for the zuks but depending on terain the zuk axles wont hold up to the toyota power. toy axles are a perfect match but the hard part is ushualy finding the front axle but the heep front will hold up

 

[blazinzuk]

the toyota drive train is perfeckt for the zuks but depending on terain the zuk axles wont hold up to the toyota power. toy axles are a perfect match but the hard part is ushualy finding the front axle but the heep front will hold up

I think the Toyota drivetrain sucks for a sami, the axles yes but samis can rely on gearing or a 1600 16v swap for a bit more power.

The toy motor is big and heavy one of a zuks best points is the fact they are so light and small.

If you are breaking cases often I have put extra mounting points off of a couple different cradles

 

[n4xplay]

I compleatly agree on the weight but there achilies heal is the tcase mount and gearing all fixable items I have been threw 2 zuks but made the move to full size for a family camping rig

 

[blazinzuk]

I just starting building my own t case mounts after I figured out it was better to hard mount em. That was probably 4 years before they came out with the hard mount kit. After I ruined the bosses on both sides of the case I built a couple extra mounting holes. It was a pain to mount but I never had a problem again.

So I never considered that a problem.

Someday I will go back to zuks but 2 kids and a wife and all the associated stuff kind of needs a bigger vehicle.

I also had some other reasons for going full size.

My next zuk will be more buggy than zuk but with the whole body intact.

We shall see if I ever get around to it

 

[wasted wages]

Is it possible to drill completely thru the case and run bolts/studs from the inside out to salvage a case where the bolt holes are all wallowed out ?

I have not seen the case and the damage yet,, so I'm just brainstorming......

worst case scenario,,
what kind of damaged makes the case trash ?

If the bolts and mounting boss on the case are damaged,, will one of the aftermarket cradles make the case usable again ?

It looks like they mount by the bolts that hold the two case halves together...