Re: Wich one?? Low Low range ORD\'s Doubler or??>>>>>>
Interesting discussion but not really relevant here........
Nobody uses straight cut gears in a transfer case. Take a look on the "205 tech info" page on our site, it shows the input gears and their tooth pattern if you want to see what the 205 uses.
As for the Atlas/Klune/Doubler stuff, there is not strength question with a 205, there is with an atlas. We have sold Doublers to guys that have split the Atlas cases. They do break and you don't see it in rock crawling competition because nobody is running big power, big weight and big tires. There is nothing wrong with the atlas but keep in mind it was designed as a HD replacement for jeeps and small broncos, not a fullsize truck. And don't show me the "32 spline front output makes it 1-ton rated" deal, I'm don't really think a larger front output shaft increases the torque capacity of the case!
This doesn't mean the things automatically explode when you hit a rock, but it is possible under hard use with heavy vehicles and much more likely than busting a 205.
I've never been inside a Klune but the biggest problem I see with them in this discussion is cost. By the time you adapt the gearbox to the GM trans and the 205, you're well over $2K and don't have the transfer case yet. In a ford or jeep they make a lot more sense since you don't need extra adapters but the round bolt pattern doesn't bolt up to much in the GM world.
So, coming from a guy that builds and sells Doublers, here's as honest a critique as I can give:
Doubler Pros:
-Strength, nobody will dispute the torque capacity king is the 205, and the 203 is no slouch either. Doublers don't break. Literally. We have one broken shaft out of all our kits and it was a 27 spline version. Our shaft is also hardened so it's strong and durable, meaning the splines won't wear out in a few years. You can break the 205 output shafts in some circumstances but that usually has to do with driveshaft problems. And if you do break, parts are pretty common and available.
-Gear selection, you can have a 2:1 or 4:1, and in the future should have the 2:1, 3:1, 6:1 option with low gears in the 205. I really think this can yeild all the low gears a guy can effectively use and gives good variation for running different terrain.
-Cost, most of our customers spend a good bit less than $2K overall for a Doubler setup, and it's typically FAR less. You can get away with as low as the $740 base kit if you scrounge parts well and fab your own shifter. There are a lot of different levels depending on how much of the work you want to do yourself. Availablility is wrapped up in this, many people already have the right parts, or some of them.
-You can easily swap brands in your drivetrain, ford front axles with GM engines and trannies are becoming more common and it's easy with our kit.
Doubler Cons:
-Weight, the overall is about 230-240#. The 205 alone is about 135# and the 203 gearbox with our adapter is about 100#
-Length, the Doubler overall is longer than a single gearbox. It compares favorably with any other add-in underdrive though and typically the length is fine in a truck. It's the same as the 203 that came from the factory in a lot of our trucks, and shorter than the 208 that was also factory in a lot of our trucks.
-availability with some transmission? We can adapt to about anything but some of the adapters are hard to scrounge up and can be expensive. If you have a TH350 or TH700 though, the parts are very common and cheap.
Atlas Pros:
-Weight, the case is about 110#.
-Length, it's about 5-6" shorter than a Doubler. This can hurt the front driveshaft while helping the rear, so it can be bad or good.
-Strength is reasonable but not guaranteed for a truck. If you break, the parts come from one place.
-You can swap sides with the front diff easily.
-Slightly deeper gear ratio available in the 4.3:1 version.
Atlas Cons:
-strength is reasonable but not guaranteed for a truck.
-Cost, no matter what, you pay advance a lot. There are no parts you can find on your own.
-Single low range only. No in between gear ratios, you're either high range or low.
Klune Pros:
-2.72 low gear is a little lower so you have another ratio available and the overall low is lower than a standard 2:1, 2:1 setup. But with lower 205 gears available this is not an issue.
-bolts in easy if you have a ford......
Klune Cons:
-Cost is huge in a GM.
-I don't know about the strength, it's probably fine.
-putting the lower gears in front of the 205 isn't the smartest place. The lower gears belong in the t-case for best strength.
So, there you go.
