Skipping 2.) for now other than to say go to
http://subarubrat.com , find "MY BRAT MODS". The good lift info is near the bottom.
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There are several transfer cases that can be used in your subaru:
1.) The Nissan 720 4x4 Pickup T-case. This is the most commonly used T-case, probably the most convenient t-case to use.
-Shares subaru flanges for easy driveline work.
-Outputs are in line vertically so driveshafts line up straight with the diffs.
-Found in '80 to '85 Datsun/Nissan 720 4x4 PU's
-Fairly tall, reduces ground clearance alot. As a result an 8"+ lift is needed to get good clearance.
Specs: High range ratio: 1:1 Low range ratio 2.27:1
2.) Suzuki Samurai T-case. -Range of reductions available, from stock to aftermarket 4, 6, and 8:1 reduction ratios.
-High range reduction ratio gives better gearing for big tires on the street.
-Must be clocked upright due to offset outputs, but is still shorter than a nissan t-case. Good ground clearance even with 6" lift.
-Does not share subaru flanges so custom driveline solution required.
Specs: High range reduction Pre/Post '85: 1.58:1/1.40:1
Low range reduction Pre/Post '85 2.5:1/2.2:1
3.) Suzuki LJ80 T-case -excellent reduction ratios both in high/low range
-vertically inline outputs to line up with diffs
-easy to mount
-may be weaker than datsun or samurai case
-does not share subaru flanges
-LJ80s are very rare in the U.S.
-very small.
Specs: High range reduction: 3.0:1 Low range reduction: 1.7:1
4.) Lada Niva T-case -compact size offers excellent ground clearance, can be used in a 6" lift
-FT4wd with difflock allows 4wd on pavement
-high range reduction helps on-road gearing
-offset outputs add to driveline angles but are still acceptable.
-funky mounting system
-shares subaru flanges
-very very rare in the U.S., as it is a russian car, imported to Canada.
-Donor car is the Lada Niva 4x4, an imported russian 4x4 similiar to a samurai but with independant suspension.
Specs: High range reduction: 1.2:1 Low range reduction: 2.0:1
Other known options are:
Toyota 4x4 PU t-cases with divorce kitts from OTT? Marlin Crawler??
CHIME IN PLZ but really are overkill for stock axle strength. Maybe a consideration for subarus with toyota solid axle swaps.
Divorced NP205 WAY WAY OVERKILL, heavier than a subaru block
DRIVELINES: For T-cases with subaru flanges, use datsun 720 4x4 PU drivelines and cut to required lengths.
For suzuki flange tcases, who knows? -Update: Information provided by ThreeEyedBandit, scroll to post #6