JDM Switchable transfer case question (complicated)

[IceMinion]

I have a welded center diff, and a switchable transfer case.

The car is basically underivable in tight cornering situations (parking lots)

I know I can go under the car, unbolt the retaining plate, let the "plunger" slide forward to get 2WD.

Thats great, but I want more!

I want to be able to switch from 2wd to 4wd (back and forth) in the cab, but I want to do this without damaging the transfer case (because they are so rare)

I plan on building a bracket and a cable (or use an electric solenoid)

but I need to know:
1. How strong do I need to build the shifting mechanism
2. How much slop can I have, is the answer in thousands of an inch or "close enough"
3. can I switch while driving? (probably best to do it in a slight turn, so whatever "syncro" or "teeth" that make this thing work, can align themselves)
4. am I going to blow it up? (my car should dyno in the 400WHP plus catigory)

Thanks

 

[AWD_Hybrid]

I used an extra auto shifter to link a cable to the pin on the transfer
case. It only has to pull 3/8" to overlap the rear shaft for awd.

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You can release awd to fwd on the fly, but fwd to awd, you have to
stop, turn the steering wheel to full lock, slowly move forward while
moving the gear shift to realign the splines. Easy when you get used
to it. Mine is a locked lsd awd 1G Auto with a switchable transfer case.
The front section of an Auto case needs machining to bolt up to the
manual mid-tail section. I can advise how to if anyone wants to.
You need 8mm more rear tyre circ to make up for the 1.09 undergearing.
My DD runs 215-45-17 front & 245-40-17 rear to compensate the ^^^
AWD 50/50 drive with lsds both ends needs the above ^^^
Cheers !

 

[snakeyes711]

dude! Thats bad ass!

 

[AWD_Hybrid]

Thanks ! That's my Monte Carlo Auto VR4 DD. I was going to Hybrid it, but
I brought an awd Lancer to got all out on. I have a few switchables & the
Lancer will have an 8" DC mid tailshaft. Profile tells the build I'm up to.
Cheers !

 

[matthewdesigns]

That's pretty slick AWD_Hybrid. Monte Carlo VR4? Please explain...without hijacking this thread too much if possible. And I think we need a build thread on the electric RWD setup when you get it started

 

[toofast82]

very nice