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  • June 16, 2019, 09:08:55 PM

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Author Topic: RallyEagle's 82 SX4 Rally car rebuild  (Read 4441 times)

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Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #135 on: May 18, 2019, 08:36:05 PM »
I've been traveling a bit but I finally got to put the 235/75r15 tires and rims on.  Noticeably different stance, look and speed.  The 4.10 axles still churn up the gravel with the 390 in front.  What a blast to drive.  Might change rear to a locker and then add a 242 tcase.  Time will tell.




Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #136 on: May 27, 2019, 07:17:56 PM »
Since I have and early humvee  AMG 242 tcase which is 4wd only with Hi lock, High, Neutral and Low lock, I will install it in my SX4.  I split the case and removed innards. Will install new seals. Then I'll drop the AM119 and compare input shafts to see what I need to do.  The transmission is a 727 3 speed.  Novak adapter on order as well.
« Last Edit: May 27, 2019, 08:35:07 PM by RallyEagle »

Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #137 on: June 04, 2019, 06:09:06 PM »
Tore my NOS hmmwv NP242 transfer case down, replaced input drive gear and seal. Waiting on seal extender and speedometer drive gear. Then I'll set the tcase and connect the shift linkage to determine floor cutout location for shifter handle. Then I'm going to use a hmmwv rear drive propeller with slip yoke and have it fitted to length.
« Last Edit: June 04, 2019, 06:09:40 PM by RallyEagle »

Online amarshall

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #138 on: June 05, 2019, 11:36:20 PM »
I’ll be interested in pictures of your shifter solution.  I hacked mine together and it works, but I need to come up with a cleaner solution for a boot.
Wanted:  More time to work on my Eagle!

1988 Eagle Wagon - Overlander Build
http://forums.amceaglesden.com/index.php?topic=45852.0

Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #139 on: June 06, 2019, 09:23:05 PM »
Sure, I'll post pictures once I get it fitted.  It seems the transmission shift linkage maybe in the way.  Should have progress on it next week.

Online amarshall

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #140 on: June 07, 2019, 10:30:32 PM »
If you are using the Novak shifter I posted about...I do recall that I had to modify the trans shift linkage to clear the Novak bracket.  Details are fuzzy, but I think I was able to flip the direction of the linkage 180 degrees and get it to clear.  I think the lock nut was the biggest hang up, I was able to flip that around.  It’s tight, but it works.
Wanted:  More time to work on my Eagle!

1988 Eagle Wagon - Overlander Build
http://forums.amceaglesden.com/index.php?topic=45852.0

Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #141 on: June 08, 2019, 07:15:07 AM »
Thanks for tip.  On this retrofit, it seems everything is fighting me! I have a 727a transmission so the seal extension requires a bushing to press into the housing correctly.  Then the Dana 35 yoke with 1330 I have has too small of a seal boss. I have to change that so that i can cut down my propeller.  Once the tcase is in I can then figure out the shifter. Fun stuff! Pictures when I'm getting close.

Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #142 on: June 09, 2019, 05:14:37 PM »
Since its raining again, I spent time prefitting the shift adapter for the NP242 tcase and bending the shaft. Tight fit up there and the 727 linkage needed adjusting as well.  Once the tcase is installed, I hope I can get my hands in there to tighten the stuff up. Enjoy the pictures.











Online amarshall

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #143 on: June 09, 2019, 10:44:42 PM »
Looking good!  You kept that slot really small, almost hard to believe that is enough to get the shifting done.  I cut a huge panel, maybe 8x8 and got it all tweaked by working from above.  It was still tight but at least it gave me another angle to get in there.  After everything was adjusted, I cut a slot in the panel and put it back in place with some bar stock as a flange.
Wanted:  More time to work on my Eagle!

1988 Eagle Wagon - Overlander Build
http://forums.amceaglesden.com/index.php?topic=45852.0

Offline RallyEagle

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Re: RallyEagle's 82 SX4 Rally car rebuild
« Reply #144 on: June 10, 2019, 06:58:36 AM »
Thanks. It might require enlarging however the linkage is close to the cut out and as long as possible on the connecting link arm, so a smaller throw is needed. I measured as best I could without tcase in. The slot was made with a unibit and recip saw. It is going to be a challenge to tighten things in there.

 

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