FJ Cruiser geared tcase & crawl box by Inchworm
01-18-2007, 09:30 PM
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FJ Cruiser geared tcase & crawl box by Inchworm
I dropped off my FJ Cruiser a few weeks ago with Jim at Inchworm to have it slowed down a little... 
Jim wanted to do some testing/prototyping on an FJC with his new gear driven tcase and adapters and I wanted lower gears. I had their new driver side drop geared transfer case (a.k.a. Lefty) along with a crawl box installed. The front reduction box has 2.28:1 gears and the tcase has 5:1 gears. The AT FJC's stock crawl ratio is 33:1, with the Inchworm setup I am now at 168:1. Also installed are a set of triple sticks that come up through the floor in the original tcase lever position, so no cutting was necessary. Jim also did a test fit of just the geared transfer case and it will install without modifying the gas tank or drive lines. The geared tcase is a great solution for folks that want to run lower gears, but don't want/need double tcases.
And lastly, but certainly not least, Jim and him team are great to work with... I am very pleased with my experience and will do more business with them in the future.
Here are a few pictures of the setup as it was being installed. I will post more information and pictures once I get my FJC back this weekend.
Gear driven transfer case plus the reduction box and adapters:
In the picture below you can see the FJC exhaust cross-over pipe and how flat it comes from the factory. I will be moving the cross-over pipe now that I have more room.
The belly of my FJC is now just about completely flat. Remove the factory cross-member and re-route the exhaust cross-over pipe and it will be flat:
The gas tank in the FJC's is very close to the stock tcase and must be shortened to install double cases. A plastic welding company was able to shorten the gas tank by 3". The 3" is equates to 1 gallon less capacity, which to me is worth it for the lower gears.
Chopped gas tank:
Clearance between tcase and gas tank after install:
Jim wanted to do some testing/prototyping on an FJC with his new gear driven tcase and adapters and I wanted lower gears. I had their new driver side drop geared transfer case (a.k.a. Lefty) along with a crawl box installed. The front reduction box has 2.28:1 gears and the tcase has 5:1 gears. The AT FJC's stock crawl ratio is 33:1, with the Inchworm setup I am now at 168:1. Also installed are a set of triple sticks that come up through the floor in the original tcase lever position, so no cutting was necessary. Jim also did a test fit of just the geared transfer case and it will install without modifying the gas tank or drive lines. The geared tcase is a great solution for folks that want to run lower gears, but don't want/need double tcases. And lastly, but certainly not least, Jim and him team are great to work with... I am very pleased with my experience and will do more business with them in the future.
Here are a few pictures of the setup as it was being installed. I will post more information and pictures once I get my FJC back this weekend.
Gear driven transfer case plus the reduction box and adapters:
In the picture below you can see the FJC exhaust cross-over pipe and how flat it comes from the factory. I will be moving the cross-over pipe now that I have more room.
The belly of my FJC is now just about completely flat. Remove the factory cross-member and re-route the exhaust cross-over pipe and it will be flat:
The gas tank in the FJC's is very close to the stock tcase and must be shortened to install double cases. A plastic welding company was able to shorten the gas tank by 3". The 3" is equates to 1 gallon less capacity, which to me is worth it for the lower gears.
Chopped gas tank:
Clearance between tcase and gas tank after install:
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