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Author Topic: Stub axle  (Read 940 times)

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Offline RedneckInTraining

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Stub axle
« on: May 17, 2010, 05:17:49 PM »
I am trying to put a perkins 2.2L diesel in a 88 mitsubishi mighty max 4x4.After separating the mitsubishi transmission/transfer case I was able to determine that the mitsubishi transfer case can be divorced quite easily to allow the 2wd diesel transmission to connect to it.The transfer case's input is set up for a female 24T 1" spline.So I was thinking of using a U joint and yoke that will fit the diesel transmission then weld the input shaft from the mitsubishi transmission to the back side of the U joint(IE wear it slips into the axle tube to be welded.

I am just not sure if the steel splines would hold up after being welded.The stub shaft would be about 9" long with about 4" unsupported in the middle.

so it would go:
diesel/transmission-stub shaft-transfer case-drive shafts.

The engine makes about 50 HP and 90 lb-ft of torque,but I will be adding a turbo to the diesel which should bump it up to about 80 hp and 150 ish lb-ft.

so the shaft will have to hold up to that,plus whatever the gearing adds,then the weight of the vehicle...

Any idea if it will be fine or is there a way to heat treat the weld area to bring the strength back?
1994 Dodge Ram 2500 CTD
1987 Dodge Dakota 3.9 V6

                      RON PAUL- 2012
Governments control people. Who CONTROLS the GOVERNMENTS of the people?

Offline ChrisKD

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Re: Stub axle
« Reply #1 on: May 17, 2010, 07:36:25 PM »
The Transmission (KM145 5-Speed) itself has shift rods running through the Transfer Case Adapter and Transfer Case, and the Transmission shifts through the top of the T-Case.

Without the Rods installed, it'll leak gear oil out of 3 Holes in the front of the Transfer Case.   If you want to divorce the KM100 Transfer Case, you'll need to get the T-Case from an Automatic equipped Ram 50 / Mighty Max.  Or plug each of those holes (also there is an additional hole near the top on the front of the t-case, it'll need plugged aswell)
76 Ramcharger 318/727/203
48 Dodge Pickup
83 Scamp GT 2.2 Turbo AWD
92 Dakota 5.2/518/231
84 PW50 273/727/100/203
74 Duster 6-71 Blown 340/833/D60
73 Duster 340/727/8.75
73 Dart Sport 340/833/8.75
73 Dart Sport 340/727/8.75
71 Duster : Viper V10/6-Speed/8.75
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Offline RedneckInTraining

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Re: Stub axle
« Reply #2 on: May 17, 2010, 08:04:04 PM »
There was only one hole at the top of the transfer case for the transmission shift rod,and then the input.I will be plugging that hole.As for connecting the transmission I was thinking of cutting off a piece of the tailshaft of the transmission then welding that to a u joint that fits the diesel transmission.Then modify the transfer case shifter so it sits where it is supposed to.
1994 Dodge Ram 2500 CTD
1987 Dodge Dakota 3.9 V6

                      RON PAUL- 2012
Governments control people. Who CONTROLS the GOVERNMENTS of the people?

Offline ChrisKD

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Re: Stub axle
« Reply #3 on: May 19, 2010, 01:34:32 AM »
There was only one hole at the top of the transfer case for the transmission shift rod,and then the input.I will be plugging that hole.As for connecting the transmission I was thinking of cutting off a piece of the tailshaft of the transmission then welding that to a u joint that fits the diesel transmission.Then modify the transfer case shifter so it sits where it is supposed to.

Welding directly to a U-Joint is something i wouldnt recommend. What you want is a Yoke to fit your U-Joint.  Put the Yoke on a Lathe and cut a pocket in the center, so that the "Stub" is an Interference Fit before welding.  As far as balance goes, that's something you'll have to work with

Also keep in mind that the Transfer Case Shifter will be harder to modify, it's actually a Little tiny Stub of a Shifter, with a large chunk of rubber mounted to it, and a sheet metal "shifter" is slipped over the rubber mold and held in place with an E-Clip  ;)  It's no Steel Rod like the Transfer Case Shifters you're used to

I tore apart a few of em and built a custom T-Case Shifter for my Diesel, Tearing them apart is a challenge. You have to remove the E-Clip, then heat the Sheet Metal Casing with a Torch to seperate the glue that bonds the rubber to the metal. While twisting the casing to pull it off.
« Last Edit: May 19, 2010, 01:39:27 AM by ChrisKD »
76 Ramcharger 318/727/203
48 Dodge Pickup
83 Scamp GT 2.2 Turbo AWD
92 Dakota 5.2/518/231
84 PW50 273/727/100/203
74 Duster 6-71 Blown 340/833/D60
73 Duster 340/727/8.75
73 Dart Sport 340/833/8.75
73 Dart Sport 340/727/8.75
71 Duster : Viper V10/6-Speed/8.75
71 Demon 8-71 Blown 540 Hemi/833/D60
72 Demon 340/833/8.75
65 Cuda 273/904

Offline RedneckInTraining

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Re: Stub axle
« Reply #4 on: May 19, 2010, 02:43:36 AM »
wouldn't it be simpler for mitsubishi to simply make a metal rod for the shifter and then call it a day?
1994 Dodge Ram 2500 CTD
1987 Dodge Dakota 3.9 V6

                      RON PAUL- 2012
Governments control people. Who CONTROLS the GOVERNMENTS of the people?