Astro AWD "Stroverlander"

[mapper]

While perusing the pick/pull yard, I came across a few NP233 transfer case candidates so when budget allows will pull one with wiring/tccm/switch... :088:

I keep leaning more and more in this direction myself, so would love to see you go for it!

Thus far the van has done everything I've asked of it but it would be nice to have a little more capability "on tap". Thinking a LSD may be a more prudent first step...decisions

 

[Stroverlander]

Nice van!
It's "Bread Van" here by the way. Gotta tell you, I've spent the last couple of weeks agonizing, again, over whether or not I want to ditch the Astro in favor of true SUV. Been poking around reading about Monteros, Troopers, 4runners etc. Been doing lots of measuring, calculating, etc and, any way you slice the Astro has nearly twice the cargo volume of any of those. When 2 people are travelling, with 3 dogs between us now, I just can't see giving up the space. Love the Astro, Hope yours is still treating you well!

Hey, mapper/Bread Van, how've you been? Nice to see another Astro/Safariite over here. I know where you're coming from and went through the same thing before buying this one and the van is just too practical. Don't get me wrong, the others you mentioned are great expo platforms but I know what you mean about the space requirements. My van is doing well, no complaints except for a recent small leak developing from the oil pan gasket (fun fix on awd!). How 'bout your van? Think you're gonna hold onto it awhile or go in a different direction?

I've been considering one of these for use between the seats. Wouldn't be too tough to add another layer...like a security drawer or something similar under it...and bring it up to armrest height.
http://www.tuffyproducts.com/c-56-universal-consoles.aspx

My only hesitation at the moment is that I like having that spot clear for walking to the back and placing a small snack cooler for trips.

That's a good idea and could be handy as storage space is so limited up front, there just isn't much room to store anything. That's why I picked up a factory slide out under seat storage bin at the PnP for the passenger seat. I like having that space to walk through as well, though usually the cooler isn't too bad to slide out of the way to get through. If you decide to go that direction in the link, I'd like to see what you end up with and how you like it.

I keep leaning more and more in this direction myself, so would love to see you go for it!

Thus far the van has done everything I've asked of it but it would be nice to have a little more capability "on tap". Thinking a LSD may be a more prudent first step...decisions

If you haven't already, check out T.Low's build thread here T.Low's take on transfer case swap 2spd electronic shift and here Build slideshow of my Astrolander

Pretty good primer for what's involved in the two-speed transfer case swap and really helped spark my interest going that direction.

It's too bad yours didn't come with the factory G80 option though you could always luck out and find one used or I've seen Eaton True Trac's for around $400 new when researching 4.10 gears and dreaming traction devices. :drool:

 

[ihatemybike]

I picked up a G80 rear axle at a scrap yard for $126 and swapped it in. Makes the van much more capable off road. Most of my Jeep buddies have open diffs still and it's fun to walk Grumpy up something that they were struggling with.

 

[digitaldelay]

I picked up a G80 rear axle at a scrap yard for $126 and swapped it in. Makes the van much more capable off road. Most of my Jeep buddies have open diffs still and it's fun to walk Grumpy up something that they were struggling with.

Hey Aaron:

My Safari has 3.42 gearing. If I found a G80(3.73) I would have to do something to the front too, right?

Jason

 

[mapper]

Hey, mapper/Bread Van, how've you been? Nice to see another Astro/Safariite over here. I know where you're coming from and went through the same thing before buying this one and the van is just too practical. Don't get me wrong, the others you mentioned are great expo platforms but I know what you mean about the space requirements. My van is doing well, no complaints except for a recent small leak developing from the oil pan gasket (fun fix on awd!). How 'bout your van? Think you're gonna hold onto it awhile or go in a different direction?

That's a good idea and could be handy as storage space is so limited up front, there just isn't much room to store anything. That's why I picked up a factory slide out under seat storage bin at the PnP for the passenger seat. I like having that space to walk through as well, though usually the cooler isn't too bad to slide out of the way to get through. If you decide to go that direction in the link, I'd like to see what you end up with and how you like it.

If you haven't already, check out T.Low's build thread here T.Low's take on transfer case swap 2spd electronic shift and here Build slideshow of my Astrolander

Pretty good primer for what's involved in the two-speed transfer case swap and really helped spark my interest going that direction.

It's too bad yours didn't come with the factory G80 option though you could always luck out and find one used or I've seen Eaton True Trac's for around $400 new when researching 4.10 gears and dreaming traction devices. :drool:

Hey, yeah. I've been a lurker here for awhile and keep slowly trudging along toward the dream...which is leaving the job for an extended period of travel/exploration. :wings:

I don't post enough (reading and trying to actually get out) but I actually get a lot of small trips in...I live in a great place for that. Basically I think of each trip as a small experiment and shakedown for platform/ideas. My goal, always, is to keep it simple. I started doing my trips in my 2WD Passat wagon...been all over the country in that thing but limited capabilities, of course, still you'd be surprised where it can go. It actually has an electronic diff lock that operates below 25mph...pretty sweet little piece of gear that really keeps the car on the go. A person can really cover a lot of ground, all but the nasty trails, in a simple car like that. So I recently bought a Volvo XC70 to try bridging the bap btw 2wd wagon and big ole Astro Van. Still not capable of the nasty trails but much more confidence when encountering mud, snow, or a lesser maintained roads. Was hoping to take advantage of somewhat better MPGs, was disappointed because once loaded and driven at cruising speed I was only getting 20-22 mpgs but ahh, the comfort! That said the Astro does a lot of things well and I can squeeze 18 to almost 20 mpg if I keep light on the gas. Still I long for low range and feel like an SUV is just a little less gas mileage and "not too much worse"...oh trying to find the perfect middle ground. Meanwhile I sit trying to maintain 3 vehicles and not knowing which one to go "all in" on building. :smilies27

Meanwhile they all serve a small niche pretty well. That said I could see a Trooper being a nice compromise.

My van is doing well passed 210k last week. I do what I can to keep it going strong and ready for a trip anytime...really need to post up some more recent pics. My Astro oil drip seems to be coming from where the engine and trans meet, by those two little rubber outlets, just above the oil drain plug. Guessing it's the rear main seal. Before I attempt anything big with that van I'd want to rebuild the trans anyway so I'm just letting it be for now.

Definitely seen T Lowe's stuff...can really see going that route but have to make sure the van is the platform for me before I dig into my trip savings stash.

 

[mapper]

I picked up a G80 rear axle at a scrap yard for $126 and swapped it in. Makes the van much more capable off road. Most of my Jeep buddies have open diffs still and it's fun to walk Grumpy up something that they were struggling with.

More Off Topic, sorry Strover.

Hey Aaron, That's the route I'll probably be looking toward. Lot of vans in the yard around here and I think LSD would be a common option for our weather/terrain.

BTW, I saw somewhere you took Grumpy on 7 mile rim, good job! I recently drove to visit mom in Phoenix and took a quick side trip on the access road for 7 mile and other trails. I walked up the initial climb for 7 mile rim with the pups. Impressive knowing you got the Astro up there. :luxhello: It's one of those trails I though would require a more capable platform, you know how to handle that van!

If you make it back this way on another trip give me a shout. I'm always trying to get out and explore.

 

[Stroverlander]

Hey Aaron:

My Safari has 3.42 gearing. If I found a G80(3.73) I would have to do something to the front too, right?

Jason

Yes, or you could use your 3.42 ring and pinion with the G80.

 

[Stroverlander]

More Off Topic, sorry Strover.

Hey Aaron, That's the route I'll probably be looking toward. Lot of vans in the yard around here and I think LSD would be a common option for our weather/terrain.

BTW, I saw somewhere you took Grumpy on 7 mile rim, good job! I recently drove to visit mom in Phoenix and took a quick side trip on the access road for 7 mile and other trails. I walked up the initial climb for 7 mile rim with the pups. Impressive knowing you got the Astro up there. :luxhello: It's one of those trails I though would require a more capable platform, you know how to handle that van!

If you make it back this way on another trip give me a shout. I'm always trying to get out and explore.

No worries here, good convo... :REOutCampFire03:

 

[mapper]

Yes, or you could use your 3.42 ring and pinion with the G80.

Oh wait, the G80 isn't tied to the gear ratio? Crap, there was a G80 for sale on line here for awhile, I totally should have snagged it.

So, for a shadetree kind of guy...would you recommend simply swapping out axles, with the same gearing OR adding the G80 to the existing rear end. That's probably a question for AstroSafari

And since you appreciated the conversation....
7 Mile Rim Trail begins

View from east toward Arches from the top of the first climb. You can see my little Volvo down below, just left of the power line pole.

 

[digitaldelay]

Yes, or you could use your 3.42 ring and pinion with the G80.

OK, that's good to know!

Thanks,

Jason

 

[Stroverlander]

There are few used 10 bolt 7.5 / 7.625 G80 locking units on eBay without gears for $100-$150 and would save having to pulling one yourself. I'm certainly no expert having never done one but having researched considerably, I feel confident to tackle the job if/when the time comes (gear swap, G80 rebuild or replace with aftermarket unit). Lots of installation info over at astrosafarivans.org too.

Here's how this particular unit (Eaton automatic locking differential) works:
[video=youtube;tTGZOJQQBeE]http://www.youtube.com/watch?feature=player_embedded&v=tTGZOJQQBeE[/video]

 

[ihatemybike]

G80 (positive traction/limited slip) doesn't specify the gear ratio. In the Astro it is most common to find it paired with 3.42 (GU6) gears, however you can also find them with 3.73 gears (GT4). Finding a G80/GT4 van in the scrap yard will most likely be an AWD van and I would pull both the rear axle and front differential to swap them both. The GT4 gears were rarely found in the 2WD vans.

https://sites.google.com/site/astrosafariworld/drivetrain/awd
https://sites.google.com/site/astrosafariworld/drivetrain/front-differential

 

[ihatemybike]

Just noticed page 9 of this thread.

7 Mile Rim was fun. My plan was to drive it as far as I felt comfortable. Running solo in a 14 year old beat up van with 1/3 tank of gas, as it wasn't my original plan to run any trails, I didn't want to take any chances. I kept things slow and was careful with wheel placement. Really wish I had the GPS tracks from that.

Swapping axles on these vans is actually pretty easy and definitely less of a headache than having set the gears up. Front diffs require their removal to re-gear it and while the rear can be re-geared in vehicle, I'm told it's much easier to do on the bench.

 

[ben2go]

Catching up.The Astro is looking sweet.It's hard to find AWD Astros and fullsize vans.

 

[Stroverlander]

One thing to consider with '03-'05 disc brake rear axles is the axle diameter hub at outer end of tube is a larger diameter - larger bearing/seal, different flange for disc brake backing plate and the obvious 6-bolt axle shaft hub. I first noticed the difference while looking up part numbers for bearings and seals.

I agree that pulling the rear end instead of working on it under the van seems a better option.

Aaron, it's pretty cool you tackled 7 mile rim with Grumpy. :friday:

Mapper, nice view from up there and I bet the dogs enjoyed that romp.