2G Dog Box Issues

[Mham2k]

So I bought a Dogbox from someone and didn't realize that the 91 trans case wouldn't fit in my 2g so and I found that it has a Quaife QDH7B in it which takes 27 spline axles.

Can anyone give me good answers on the following

1.) Where do I get 27 spline axles to fit that fit this Quaife? What car do they come from. They are larger in diameter than my 2g axles.

2.) What do I need to get machined in my 2g case to for the ppg dogbox? I know the input shaft is larger not exactly sure what to machine it to and what seal to get for it. Maybe EVO 3 seal?

3.) Where can I get a good set of new bearings for the trans.

If I can just pay someone to machine the case and ship it back that would be great.

 

[jdxnc]

I've never seen 2g front axles with a different spline count, not sure what you solution there is.

Does your car have a 6 bolt block? If so, a buddy of mine made custom roll stops to bolt to the block rather than the transmission like in a 1g, that's how he got around using a 1g transmission in his 2g, other alternative is to swap the bellhousing but that's a pretty involved process, especially with the PPG gearset.

TRE, TMZ or Jacks should have the bearings for you.

 

[Mham2k]

I've never seen 2g front axles with a different spline count, not sure what you solution there is.

Does your car have a 6 bolt block? If so, a buddy of mine made custom roll stops to bolt to the block rather than the transmission like in a 1g, that's how he got around using a 1g transmission in his 2g, other alternative is to swap the bellhousing but that's a pretty involved process, especially with the PPG gearset.

TRE, TMZ or Jacks should have the bearings for you.

After doing a little research it seems the 27 spline axles are 2g FWD axles, i may be able to make the passenger side work but the drivers side FWD axles is long and the AWD is short with the intermediate shaft in there. Is there a 27 spline intermediate shaft? If not the diff won't work for me and I probably need to sell it and get another one.

I do have a 6 bolt block, I read that a few people did that but it was very Involved.

I can weld but not trained, don't really want to go that route.

I would rather put it in the 2g housing so it works as it should.

I think the transmission overall would be worth more in the future as well.

 

[twicks69]

Well, the QDH7B uses 2G FWD 27 spline axles, which requires machinework to the bellhousing to fit it in correctly for the left axle location axle seal. Then if you are using tapered roller bearings, you need to machine the bellhousing bore depth another ~0.060" or so to get the gear mesh to line up correctly for the front diff ring gear and output pinion shaft. I did this for Andrew Brilliant's FWD dogbox on his time attack car many moons ago. I am suspecting the previous owner was using this trans in a 2G FWD car. There are no 27 spline halfshafts so you would have to integrate 2g FWD unequal length axles.

As for the PPG, you can carefully shave or bore the input shaft sleeve with the proper sized drill bit in a vertical mill or drill press with it fixtured. It still uses the OEM MD741818 input shaft seal.

You also need to clearance grind the reverse idler lever and input shaft oil slinger, and then I typicallly radius 1st gear on the input shaft to provide additional clearance for the reverse idler lever, and sometimes the backside of the reverse idler gear depending on how it fits.

For a transmission case, you will require a 2g AWD DSM case. Front and rear motor mounts are attached to the N-S bar on the bellhousing.

 

[Mham2k]

Well, the QDH7B uses 2G FWD 27 spline axles, which requires machinework to the bellhousing to fit it in correctly for the left axle location axle seal. Then if you are using tapered roller bearings, you need to machine the bellhousing bore depth another ~0.060" or so to get the gear mesh to line up correctly for the front diff ring gear and output pinion shaft. I did this for Andrew Brilliant's FWD dogbox on his time attack car many moons ago. I am suspecting the previous owner was using this trans in a 2G FWD car. There are no 27 spline halfshafts so you would have to integrate 2g FWD unequal length axles.

As for the PPG, you can carefully shave or bore the input shaft sleeve with the proper sized drill bit in a vertical mill or drill press with it fixtured. It still uses the OEM MD741818 input shaft seal.

You also need to clearance grind the reverse idler lever and input shaft oil slinger, and then I typicallly radius 1st gear on the input shaft to provide additional clearance for the reverse idler lever, and sometimes the backside of the reverse idler gear depending on how it fits.

For a transmission case, you will require a 2g AWD DSM case. Front and rear motor mounts are attached to the N-S bar on the bellhousing.

Sounds like the ppg stuff will be easier than I thought. I think I'm reading that really the only thing I need to do is clearance the input shaft sleeve. The gears should be good to go because they came from a working dogbox. I have the entire trans so I can swap most of the things you mentioned.Thank you @twicks69

The diff may be a problem. The forums tell me the driver's side fwd axle will not fit because it hits the transfer case, I haven't tried this myself. Have you seen anyone solve this problem? If so how?

If it's a small hit that takes a little grinding I can deal with that, if I need to cut and weld I would rather sell this and buy the correct diff.

If I buy the QDH8B do I need to do any of the machine work inside of the trans?

 

[twicks69]

I would use AWD axles, and a Quaife QDH8B differential with the correct bearings and speedo gear for the job, and sell the QDH7B.
Is the trans currently disassembled where you could take detailed photos of components so I could give more effective recommendations for what you need to deal with?

 

[Mham2k]

I would use AWD axles, and a Quaife QDH8B differential with the correct bearings and speedo gear for the job, and sell the QDH7B.
Is the trans currently disassembled where you could take detailed photos of components so I could give more effective recommendations for what you need to deal with?

I disassembled them both yesterday, I will send some pics later today.

 

[Mham2k]

The dogbox stuff is below, ppg tells me the gears are a V2.

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The this is my bellhousing for my 2g stuff, it is a bone stock 2g trans what I pulled out. The synchros were going but everything else was fine

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[Mham2k]

I mixed up some pics but I think it's clear which is which

 

[twicks69]

Yeah, you have a shitshow. You have AWD axle seals with a FWD diff. I would really need to see it in person and fix the problems you are dealing with.

 

[Mham2k]

Yeah, you have a shitshow. You have AWD axle seals with a FWD diff. I would really need to see it in person and fix the problems you are dealing with.

I'm getting rid of the diff and getting the AWD diff.

Actually it seems that the Quaife units break and a spider off is better. Will go that route first.