Divorced tcase and stock rear diffs/cv axles

[SquigSprinter]

Hey folks 

For those of you who have gone down the path of putting a divorced transfer case and using a rear diff (plus fabrication) to serve as a front diff, how well do the diffs and cv axles hold up to the additional low range gearing? For context this is using the newer VA type 2 r160 diffs found in the Ascents and Outback Wilderness (with the 4.44 final drive) and newer style CV axles that don't have the stub out for the inner CV assembly. This would be getting mated to a Subaru dual range with 1.44 reduction

Mostly curious if something like the Suzuki tcase with the extra low range gearing will be too low for the rest of drivetrain. If you've done this mod before, how well did the rest of the drivetrain hold up?

[el_freddo]

I have not done this and those that did this years ago are most likely long gone from the forum. 

One of the biggest factors is your driving style and mechanical sympathy. 

With a dual range gearbox and the dual range divorced transfer case and the addition of 4.44:1 diffs, you could run larger tyres and crawl really slowly - best of both worlds. 

What vehicle are you putting all of this into? If a vehicle with an AWD, you’ll need to weld the centre diff. Being a 1.44:1 low range it’s either an MY chassis or the sf forester (but I didn’t think you guys got the dual range gearbox from factory in the states). 

[SquigSprinter]

Aye the welded center diff would be required in my case (this is a 23 Crosstrek with the dr 5mt swapped in, it has the viscous coupling center diff and came with 4.44 final drive stock)

If I go with the Samurai tcase I plan to upsized tires to 31s to take advantage of the hi range reduction

I know the older stub style cvs tended to explode from too much torque, this would be using newer style Subaru CV axles. I mostly want to avoid getting all of this low gearing in place and then start popping diffs/CV axles.

[el_freddo]

That sounds awesome. What size lift will you run in the cross trek? 

Should be an interesting and capable vehicle!

[SquigSprinter]

I'd try 6 inches first (Raceworks coilovers can get me to that height without top hat spacers). Between that and 31s I would hope to regain the clearance lost from the front diff getting mounted.

We'll see how the fab goes in the front, my plan is to order a rear subframe and cut/modify it to incorporate in front control arm mounts and build up the front subframe from this