t case Mystery Cache

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Every 4WD vehicle uses a transfer case to split the drive coming from the transmission into two outputs, one directed to the front axle and one directed to the rear axle. Most transfer cases that we are familiar with are two-speed versions, having a high-range and low-range gear set.

The high-range is most often a 1:1 ratio. That is to say that for every revolution of the transmission output shaft, the front and rear transfer case outputs rotate one revolution. Factory low-range ratios can vary from about 2:1 to about 4:1. This means that the road speed in low-range is reduced by a half or by a quarter. With this reduction in speed we gain an increase in torque by the same factor.

Transfer cases have come in both gear drive and chain drive versions. Typically a chain drive case is a bit quieter, but a gear drive case is most often stronger and does not suffer from chain wear, which requires periodic replacement. Low-range reductions come in two flavors as well: gear-to-gear reduction or a planetary gear reduction assembly.

Here is a list of specs for a few of the more common transfer cases that off-roaders use, swap, or modify. I've tried to included input/output shaft spline counts, specify the types of driveshaft mating, and give some idea as to the extent of aftermarket support available to these T-cases (ranging from low to high).

Dana 300
Manufacturer: Dana-Spicer
Number of speeds: Two
High: 1:1
Low: 2.62:1
Case (or housing) material: Cast iron
Front output drive type: Gear (driver side drop)
Availability or aftermarket parts and support: High - Twin stick setup, JB Conversions Lo-Max 4.0:1 low-range for the increase in strength where needed, and heavy-duty 32-spline front and rear outputs
Input spline count: 23
Rear yoke: Fixed
Planetary gear: No
Available U-joint sizes for yokes: 1310
Output shaft spline count: 26
Shifter type: Mechanical
Weight: ~86 pounds
Length: ~10.5 inches or 11.625 inches (mount face-to-yoke center)
Commonly found in: '80-to-'86 Jeep CJs, 1980 IH Scout

NP231 / NP231HD
Manufacturer: New Process Gear
Number of speeds: Two
High: 1:1
Low: 2.72:1
Case (or housing) material: Aluminum
Front output drive type: Chain (driver or passenger side drop)
Availability or aftermarket parts and support: Medium - heavy-duty slip yoke eliminator kits, Novak mechanical shifter
Input spline count: 21, 23, 26 or 27
Rear yoke: Slip
Planetary gear: Yes (three-pinion)
Available U-joint sizes for yokes: 1310
Flange or slip yoke eliminator available: Yes
Output shaft spline count: 27
Shifter type: Vacuum
Weight: ~70 pounds (~80 pounds for HD version)
Commonly found in: '88-to-'97 Jeep XJ, YJ, '86-and-up Jeep TJ, '88-and-up Dodge Dakota, '88-to-'97 GM T-Series

Suzuki Samurai
Number of speeds: Two
High: 1:1
Low: 2.268:1
Case (or housing) material: Aluminum
Front output drive type: Gear (passenger side drop)
Availability or aftermarket parts and support: High - Multiple available low gear sets
Input spline count: 26
Rear yoke: Fixed flange (passenger side drop)
Planetary gear: No
Shifter type: Mechanical
Length: ~9 inches mount face-to-flange
Commonly found in: '86-to-'95 Suzuki Samurai

Toyota RF1A
Manufacturer: Aisin Seiki
Number of speeds: Two
High: 1:1
Low: 2.28:1
Case (or housing) material: Aluminum
Front output drive type: Gear (passenger side drop)
Availability or aftermarket parts and support: High - Dual/triple case kits, low gears sets, twin stick kits, rear disconnect kits, chromoly output shaft 
Input spline count: 21 or 23
Rear yoke: Fixed flange
Planetary gear: No
Output shaft spline count: 27
Shifter type: Mechanical and electrical
Length: ~12.75 inches (mount face-to-flange)
Commonly found in: Various '79-to-'95 Toyota Truck and '84-to-'85 4Runner

Toyota VF1A/VF2A
Manufacturer: Aisin Seiki
Number of speeds: Two
High: 1:1
Low: 2.57:1
Case (or housing) material: Aluminum
Front output drive type: Gear (passenger side drop)
Availability or aftermarket parts and support: Medium - Dual case kits, adapters
Input spline count: 23 or 26
Rear yoke: Fixed flange
Planetary gear: Yes
Output shaft spline count: 27
Shifter type: Mechanical or electrical
Length: ~12.5 inches (mount face-to-flange)
Commonly found in: Various '84-to-'95 Toyota Truck/4Runner/T-100

Atlas II
Manufacturer: Advance Adapters
Number of speeds: Two
High: 1:1
Low: 2.0:1, 3.0:1, 3.8:1, 4.3:1, 5.0:1, or 6.0:1
Case (or housing) material: 356-T6 Heat Treated Aluminum
Front output drive type: Gear (driver or passenger side drop)
Input spline count: Multiple choices
Rear yoke: Fixed
Planetary gear: No
Available U-joint sizes for yokes: 1310, 1310-CV, A1330-CV, 1350, 1350-CV, 1410
Flange available: Yes (1300, 1400 or JK Flange)
Output shaft spline count: 32 spline
Shifter type: Mechanical or cable
Weight: 110 pounds
Length: 11.8 inches (short tail) or 13.8 inches (long tail)

Atlas 4-Speed
Manufacturer: Advance Adapters
Number of speeds: Four
High: 1:1
Low: 2.0:1, 2.72:1, & 5.44:1 or 2.72:1, 3.8:1, &10.34:1 
Case (or housing) material: 356-T6 Heat Treated Aluminum
Front output drive type: Gear (driver or passenger side drop)
Input spline count: Multiple choices
Rear yoke: Fixed
Planetary gear: Yes, six-pinion helical (for secondary reduction)
Available U-joint sizes for yokes: 1310, 1310-CV, A1330-CV, 1350, 1350-CV, 1410
Flange available: Yes (1300, 1400 or JK Flange) Output shaft spline count: 32 spline
Shifter type: Mechanical or cable
Weight: 125 pounds
Length: 15 inches (short tail) or 17 inches (long tail)

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