In other news...
I am still trying to make sure this thread has most of the info my Pirate thread does.
-I am replacing my SM420 transmission with a T18. The SM420 is a good transmission but I think overall the T18 is a better overall package. The T18 does have the reverse gear bulge of the passenger side of the transmission so running a 1310 U-joint and normal front driveline is a LOT easier. I should be able to ditch my 2-pc front driveline and go back to a somewhat normal front driveline. The T18 is available with a factory adapter to the Dana18/20 transfer case. I am using the D20 version for the 4" locating bore. The overall length of the T18 adapted to a D18 transfer case is shorter than the overall length of an SM420 to a Dana 18 transfer case if you use an off the shelf adapter. Overall I think the T18 is just a better way to go....
-Time for a fully rebuilt transfer case when I install the new transmission. I bought a complete spare twin stick Dana 18 with all oem gears. I will be using to build a 'new' transfer case with the Dana 20 late model 1.25" intermediate shaft housing i have. It's time to just do it right and be done with it.....new bearings, new seals, new intermediate shaft, etc. With the new rebuilt transmission and transfer case I won't have to worry about longer distance driving anymore. I also won't have as many critical one off parts that can't be bypassed if broken.
-I decided to do something a little crazy and different for some additional gearing. I am going to retrofit a low range unit from an older quadratrac transfer case onto the pto port of the Dana 18 transfer case. It will install similar to the AA saturn overdrive, but works the opposite way. I will gain an additional 2.59:1 low range beyond the stock low range. I always like trying new things. Super deep gearing....in the 200:1 range is fun for deep deep snow and technical rock stuff. I haven't seen anyone do it yet so why not. The underdrive also has no effect on driveline length, a really good thing with an 85" wheelbase.
You can read a little bit more about it here. A friend and I have been tossing the idea around for years.
http://www.pirate4x4.com/forum/showthread.php?t=1023228
-Now that I am not trying to chase every last bit of low range out of the transmission, t-case, and axles with the addition of the underdrive, I am trying to decide if I should go with 4.88 or 5.38 gears in the axles. The current 4.30s defiantly are not low enough. I don't see 4.56s being that big of a step adding only like 100rpm or so. 4.88s are pretty much the 1st real step in gearing. 5.38s are the lowest I can go in the D30/44 axle combo. 4.88s give me about 5mph extra at 3000rpm, are a bit stronger, bit cheaper, etc.....