As we continue our buildup of Project Scrambled Adventurer, we've reached the time to install the transfer case. For this project we went to the market looking for something different that would work well, allow multiple gearing possibilities, and offer easy mounting. What we decided on after our research was a STaK 4x4 Monster Box two-speed transfer case.
One of the reasons we decided to use the STaK 4x4 two-speed transfer case is the multiple gear ratios available. Ratios include: 5.44:1 and 1:1, 4.33:1 and 1:1, and 3.75:1 and 1:1. The helical gears and shafts of the Monster Box are manufactured from ASTM Alloy 8620 and then heat-treated. Tapered roller bearings are used on all of the shafts, and caged needle bearings are used on all of the internal gears.
The STaK transfer case's housing is another huge selling point for this unit. The housing is manufactured from cast 356 alloy aluminum and hardened to a T-6 condition for strength. The walls of the housing are CNC-machined and left thick to ensure that case deflection under heavy load or acceleration is not an issue.
The STaK transfer case also offers many mounting possibilities. It's available in passenger- or driver-side front output and with a universal shifter for many variations in mounting. The Monster Box case is also clockable in 4-degree increments up to 360 degrees and is just 13 inches long, making it compact enough for shorter-wheelbase applications. Thirty-two-spline output shafts are also part of the package, along with a choice of yoke styles.
As for the install, it should be easy on a regular rig. For our project, it was fairly simple after the clocking was figured out, the spacing determined, and the measurements completed for the final installation location. We did have to remove some of the aluminum tub, though, to allow clearance for the Monster Box. But after the box was installed, it was just a matter of welding a new piece of aluminum back into the tub to allow for the Monster Box location.
The key to installing the STaK case is to make sure you have it clocked correctly for the mounting to the transfer case before installing. Otherwise, you will be lifting the box up and down several times before you find the correct clocking location. If you need the spacer, install it first then mount the transfer case and take the measurements for the drivelines. When all is said and done, this box mounts pretty easily and has a beefy design that should hold up to many years on the trail for Project Scrambled Adventurer.