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Just Differentials - Suburban HD Project
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<blockquote data-quote="Just Differentials" data-source="post: 1556788" data-attributes="member: 18343"><p>As mentioned, plans changed 10,000 times along the way it seems. Here we have the 70HD and the D60 passenger drop that I'd pulled from Gus after KOH 2014. </p><p></p><p><img src="http://i.imgur.com/cHsdsWcl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I began tearing the 60 apart. With the H1's and dually rear, and Gus being a dually with the dually front hubs- it all seemed to fit together, just needed to figure out how this puzzle would work exactly. </p><p></p><p><img src="http://i.imgur.com/kNmbYiIl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I then got a wild hair and decided I needed to make the passenger drop 60 a driver drop 60 to retain the factory 243 for a while. </p><p></p><p><img src="http://i.imgur.com/v1oofNGl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I had cut the 60 and planned to swap sides then sleeve it, truss it and get it back together to toss under the Suburban.</p><p></p><p>As time went on and I collected more parts, I realized one problem the Suburban had in stock form that I absolutely hated and just couldn't deal with. Driving the Jeep off-road with the 4.3 Atlas, coming down out of the mountains in low range was an absolute pleasure. Just toss it in gear and let it go, no worry of touching the gas or the brakes, just let it idle along as it crawled down even the steepest descents. The Suburban however was a totally different story. Coming down out of our local mountains which have a decent grade to them after bear season left me standing on the brakes in low range and a tired leg when we finally hit bottom. Low range is awful at best in this thing under it's own weight with 33" tires and 4.10 gears. It's tired I know and worn out but I needed/wanted more gearing. Towing the Jeep on the trailer coming back from elk camp was scary at best, even with brake controller and trailer brakes on both axles. Not a fun pleasurable experience coming down out of the hills there. Something had to be done. An Atlas for the Suburban would be great, but way out of the budget. I began tossing ideas around and had talked with Kris at Northwest Fab up in Canada. Some time went on and they released their new product. </p><p></p><p>Enter the new Northwest Fab Eco box:</p><p></p><p><img src="http://i.imgur.com/oRRTZO1l.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>My decision was made, this was the solution to my gearing problems. Northwest Fab came out with their new "Eco" box. What you see here is the Eco box itself, along with full billet bearing retainer set and PTO cover, and NWF shifter knobs. The idea behind the Eco box is that it's a "budget" minded doubler similar to the 203/205 setup only that being aluminum it's significantly less weight. Also, the 203/205 setup leaves you with essentially a 3 speed box due to the 1.96:1 ratios in both boxes and basically a 3.8 low range. The NWF Eco box uses the planetary set from a 231/241 transfer case setup with the 241 preferred for the 6 pinion planetary set. 241's are readily available and found in many models of trucks and easy to get. I happened to have a spare at home already so it made for a perfect fit. The Eco box mated to a 205 using a 241 planetary set offers a 1:1 high, 1.96:1 high mid range, 2.72 low mid range and a 5.33 low low setup. This gives me the options I wanted for better control on the steep stuff. </p><p></p><p>Here we have my spare 241 torn apart and gutted. I retained the VSS sensor and tone ring as well as the necessary 6 pinion planetary set and range selector from the 241. A few cuts with the sawzall and couple smacks with the hammer and it was time to cleanup. </p><p></p><p><img src="http://i.imgur.com/MXoOcWNl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Here's all the parts waiting for prep and install:</p><p></p><p><img src="http://i.imgur.com/Wji1EiQl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I won't bore you with the rebuild of the 205 as there is tons of great info already on Pirate for how to do that. Here's a great thread by boing:</p><p></p><p><a href="http://www.pirate4x4.com/forum/general-4x4-discussion/1628066-np205-rebuild.html" target="_blank">http://www.pirate4x4.com/forum/general-4x4-discussion/1628066-np205-rebuild.html</a></p><p></p><p>Of course Grumpy's work:</p><p></p><p><a href="http://www.pirate4x4.com/forum/chevy/653713-some-np205-user-info-chevy.html" target="_blank">http://www.pirate4x4.com/forum/chevy/653713-some-np205-user-info-chevy.html</a></p><p></p><p>How to twin stick by kitimatdude:</p><p></p><p><a href="http://www.pirate4x4.com/forum/general-4x4-discussion/572617-how-np-205-twin-stick-cheap.html" target="_blank">http://www.pirate4x4.com/forum/general-4x4-discussion/572617-how-np-205-twin-stick-cheap.html</a></p><p></p><p>and of course a number of others as well. Basically what I gathered is if you can dream it, Pirate has already done it so make use of the search and you just might learn something. </p><p></p><p>I did fully rebuild my 205 using the above links with all new bearings, seals, gaskets, etc. I also modified the shift rails and twin sticked it at the same time. In addition, and while I'm late to the party and a few guys have already done a few good threads, I will show a few pics of my Northwest Fab Eco box assembly. Here we start with the case itself:</p><p></p><p><img src="http://i.imgur.com/0YP8mLzl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>And excellent machining of the two halves:</p><p></p><p><img src="http://i.imgur.com/HvnZpk5l.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>This was the scariest part of the whole thing- the planetary ring is ribbed on the outside to bite into the aluminum case for grip to hold secure. You only get one shot to press the ring into the aluminum case so there's no room for error and it better be right. I used a press with heavy 1" thick arbor plate to start the ring then slowly work it into position, then when close, walked the edge all the way around a couple times to make sure it was fully seated flush and into position. </p><p></p><p><img src="http://i.imgur.com/WMVlMj6l.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Next was the input seal and retainer- the retainer is pulled from the donor 241 as well.</p><p></p><p><img src="http://i.imgur.com/Q1neLpSl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Here we have the planetary seated</p><p></p><p><img src="http://i.imgur.com/IN6GKFdl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>And finally all bolted together with addition of 3/8" quick connect breather fitting</p><p></p><p><img src="http://i.imgur.com/YbYvA6ol.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>And here we have the Northwest Fab Eco box loaded with 6 pinion planetary bolted to a fully rebuilt and twin sticked NP205</p><p></p><p><img src="http://i.imgur.com/sGrQolJl.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p></blockquote><p></p>
[QUOTE="Just Differentials, post: 1556788, member: 18343"] As mentioned, plans changed 10,000 times along the way it seems. Here we have the 70HD and the D60 passenger drop that I'd pulled from Gus after KOH 2014. [img]http://i.imgur.com/cHsdsWcl.jpg[/img] I began tearing the 60 apart. With the H1's and dually rear, and Gus being a dually with the dually front hubs- it all seemed to fit together, just needed to figure out how this puzzle would work exactly. [img]http://i.imgur.com/kNmbYiIl.jpg[/img] I then got a wild hair and decided I needed to make the passenger drop 60 a driver drop 60 to retain the factory 243 for a while. [img]http://i.imgur.com/v1oofNGl.jpg[/img] I had cut the 60 and planned to swap sides then sleeve it, truss it and get it back together to toss under the Suburban. As time went on and I collected more parts, I realized one problem the Suburban had in stock form that I absolutely hated and just couldn't deal with. Driving the Jeep off-road with the 4.3 Atlas, coming down out of the mountains in low range was an absolute pleasure. Just toss it in gear and let it go, no worry of touching the gas or the brakes, just let it idle along as it crawled down even the steepest descents. The Suburban however was a totally different story. Coming down out of our local mountains which have a decent grade to them after bear season left me standing on the brakes in low range and a tired leg when we finally hit bottom. Low range is awful at best in this thing under it's own weight with 33" tires and 4.10 gears. It's tired I know and worn out but I needed/wanted more gearing. Towing the Jeep on the trailer coming back from elk camp was scary at best, even with brake controller and trailer brakes on both axles. Not a fun pleasurable experience coming down out of the hills there. Something had to be done. An Atlas for the Suburban would be great, but way out of the budget. I began tossing ideas around and had talked with Kris at Northwest Fab up in Canada. Some time went on and they released their new product. Enter the new Northwest Fab Eco box: [img]http://i.imgur.com/oRRTZO1l.jpg[/img] My decision was made, this was the solution to my gearing problems. Northwest Fab came out with their new "Eco" box. What you see here is the Eco box itself, along with full billet bearing retainer set and PTO cover, and NWF shifter knobs. The idea behind the Eco box is that it's a "budget" minded doubler similar to the 203/205 setup only that being aluminum it's significantly less weight. Also, the 203/205 setup leaves you with essentially a 3 speed box due to the 1.96:1 ratios in both boxes and basically a 3.8 low range. The NWF Eco box uses the planetary set from a 231/241 transfer case setup with the 241 preferred for the 6 pinion planetary set. 241's are readily available and found in many models of trucks and easy to get. I happened to have a spare at home already so it made for a perfect fit. The Eco box mated to a 205 using a 241 planetary set offers a 1:1 high, 1.96:1 high mid range, 2.72 low mid range and a 5.33 low low setup. This gives me the options I wanted for better control on the steep stuff. Here we have my spare 241 torn apart and gutted. I retained the VSS sensor and tone ring as well as the necessary 6 pinion planetary set and range selector from the 241. A few cuts with the sawzall and couple smacks with the hammer and it was time to cleanup. [img]http://i.imgur.com/MXoOcWNl.jpg[/img] Here's all the parts waiting for prep and install: [img]http://i.imgur.com/Wji1EiQl.jpg[/img] I won't bore you with the rebuild of the 205 as there is tons of great info already on Pirate for how to do that. Here's a great thread by boing: [url]http://www.pirate4x4.com/forum/general-4x4-discussion/1628066-np205-rebuild.html[/url] Of course Grumpy's work: [url]http://www.pirate4x4.com/forum/chevy/653713-some-np205-user-info-chevy.html[/url] How to twin stick by kitimatdude: [url]http://www.pirate4x4.com/forum/general-4x4-discussion/572617-how-np-205-twin-stick-cheap.html[/url] and of course a number of others as well. Basically what I gathered is if you can dream it, Pirate has already done it so make use of the search and you just might learn something. I did fully rebuild my 205 using the above links with all new bearings, seals, gaskets, etc. I also modified the shift rails and twin sticked it at the same time. In addition, and while I'm late to the party and a few guys have already done a few good threads, I will show a few pics of my Northwest Fab Eco box assembly. Here we start with the case itself: [img]http://i.imgur.com/0YP8mLzl.jpg[/img] And excellent machining of the two halves: [img]http://i.imgur.com/HvnZpk5l.jpg[/img] This was the scariest part of the whole thing- the planetary ring is ribbed on the outside to bite into the aluminum case for grip to hold secure. You only get one shot to press the ring into the aluminum case so there's no room for error and it better be right. I used a press with heavy 1" thick arbor plate to start the ring then slowly work it into position, then when close, walked the edge all the way around a couple times to make sure it was fully seated flush and into position. [img]http://i.imgur.com/WMVlMj6l.jpg[/img] Next was the input seal and retainer- the retainer is pulled from the donor 241 as well. [img]http://i.imgur.com/Q1neLpSl.jpg[/img] Here we have the planetary seated [img]http://i.imgur.com/IN6GKFdl.jpg[/img] And finally all bolted together with addition of 3/8" quick connect breather fitting [img]http://i.imgur.com/YbYvA6ol.jpg[/img] And here we have the Northwest Fab Eco box loaded with 6 pinion planetary bolted to a fully rebuilt and twin sticked NP205 [img]http://i.imgur.com/sGrQolJl.jpg[/img] [/QUOTE]
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