Sprinter 4WD Conversion Idea, GMT-800 IFS.

[luthj]

As soon as I get a rough date on the subframe steel, I will put an order in for all the front end parts. Bearings, brakes, bushings, etc. Should go together fairly quick once everything arrives. Assuming I haven't screwed up somewhere, which is always a possibility. The fuel tank needs finalized, as does the trans support. Still thinking about the Tcase shifter. Not sure what direction I want to go.

 

[Len.Barron]

Cable shifter, Single, NP241, P/N NP241 CS

Cable shifter, Single, NP241, Billet style P/N NP241C

jb-custom-fabrication.myshopify.com

these are pretty highly thought of on the offroad forums...JB has always made good stuff.

 

[luthj]

I was looking at those models, they look quite good. My issue is that the Tcase is very close to the location I would want a floor mounted shifter. Hence why I was considering mounting a cable shifter backwards, and having the cable do a full 180 back to the Tcase. I will get some detailed measurements over the weekend. It may be workable with a short piece of bent rod stock, and an old school shift lever. Thought he noise transmission would be undesirable.

 

[luthj]

Trans support is drying, otherwise its finished. Dipstick/filler tube is attached to trans. Hopefully it doesn't leak. Fuel tank is finished. Well, its done, I didn't do my normal standard of hose securing and for long term the tank probably needs a couple of blocks to secure it better. Just waiting on a driveshaft now. If I finish tomorrow early, I may just drive to the junkyard and grab the slightly dented F250 shaft... It looked straight, just slightly dented on one side.

 

[luthj]

Trans is in and all hooked up.



I got in a bit of a rush, and put the paint on a bit thick. That, combined with the sun made it bubble a bit as urethanes sometimes do. Really tough stuff though. At some point I will brush on some rubberized undercoat to stop the rock chips. The rear axle is basically sandblasted, so I will need to make a project of it.



Started the van up and primed the trans. Not fuel or ATF leaks. Trans did make a bit of whirring until the packs got all wet. No trans codes, so at least the wiring is good. It took about 8 quarts to start, but I think it it will probably need another quart once the clutches and TC fill all the way.

 

[luthj]

Grabbed a temporary shaft from the junkyard. Its about an inch shorter than the ideal length, so I can't let the rear end hang or the slip yoke will be near its limit. It also has a couple small dents, so I don't want to really step on it.



Did a short drive around the block. 1-3rd and reverse gears work good. I do have some vibration when coasting. It could be the U joints on the shaft (one is a sticky). Could be the pinion angle. No odd thunks etc. I need some more ATF to completely fill the Tcase, but it looks good currently.

I will test out low range with the CANbus bridge installed later today.

 

[shade]

Congratulations on another milestone. ?

 

[luthj]

Tested in low range with the CANbridge. Works fine, no codes, all gears available up and down. The shift points are a bit funky, but I suspect they will adapt after 10 minutes in low range. The planetary set in the Tcase is audible, but the noise isn't noticeable with the windows up.

The vibration didn't change, so I assume it must be the driveshaft or pinion angle.

 

[mountainhick]

Big day! Heck yeah!

Mine's blocked up, driveshaft and tranny coming out today!

 

[luthj]

No one can say I didn't try to go local. 5 places I contacted. 2 actually called or emailed me back. None followed up with a quote for a driveshaft. I will just order from one of the mail order outfits. I think 3.5" aluminum is the only way to go with a 75" long shaft.

In other news I placed an order for all the front end wear parts. Calipers, rotors, pads, ball joints, bushings, brake lines, hub/bearing assemblies etc. Should be here next Friday, and I can get it all bolted to the knuckles.

The chassis saver adhered quite well to the trans support without primer. So my plan is to HVLP spray the subframe. I just need to remember to sand all the surfaces prior to assembly.

Didn't make any progress on the shifter today. I suspect I will need to hand fab something up. I don't really want to make the walk through area more cluttered with another handle, but there really isn't any space on the dash/console area.

 

[shade]

Didn't make any progress on the shifter today. I suspect I will need to hand fab something up. I don't really want to make the walk through area more cluttered with another handle, but there really isn't any space on the dash/console area.

Maybe use an electric actuator?

 

[luthj]

That is an option. There was an electric shift version of the 242, though I am not sure any of the parts will transfer over to the 242D. Obviously I would prefer a mechanical linkage for reliability purposes.

 

[Mwilliamshs]

That is an option. There was an electric shift version of the 242, though I am not sure any of the parts will transfer over to the 242D. Obviously I would prefer a mechanical linkage for reliability purposes.

I hear a lot about using a mechanical shifter for reliability. I have a strong background in Fords, starting with Rangers in high school, and every one has had a 4x4 button and none have ever failed to shift. I think the notion of electric shifting as unreliable is Chevy's fault for using those electric heat-driven actuators and electro-magnetic solenoids. Ford used an electric motor and gears, no reliance on springs or temperature difference there.

When someone says they don't trust an electric shifter, I ask to see their mechanical starter. How long is the manual crank handle Mercedes supplies with Sprinters? Bout the size of a car key, I imagine.

 

[luthj]

Not that I don't trust one. Its just that I will have to implement a control scheme on my own. Custom usually means less reliable than OEM.

 

[mountainhick]

I don't really want to make the walk through area more cluttered with another handle, but there really isn't any space on the dash/console area.

Some compromises can be worth it. No way I am going to mess with actuator on this manual shifted Tcase. Sometimes simple is good. We all pick our own poisons though.

Me, in a few moments I am going to lift one to the project and to you Jonathan! Thank you for being an enabler so to speak! ?

My tranny is on the ground. Tomorrow hoist it onto the bench, disassembly, check for any needed new parts and start looking at dropping rear axle!