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Author Topic: Marlin Crawler Front Chromoly Output Shaft vs. Stock  (Read 7019 times)

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BigMike

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Marlin Crawler Front Chromoly Output Shaft vs. Stock
« on: Nov 10, 2010, 07:44:30 PM »


Here is a quick and dirty comparison of our new 30-spline Front Chromoly Output Shaft and the stock front output shaft.

First some basic Q&A...
Applications: All 1979-95 Gear Drive 4cyl transfer cases
Housing Modifications required? No, simple R&R.
Same gear size/pitch/specs? Yes, fully compatible with stock front wheel drive idler gear.
Does it use the stock flange? No, it uses a larger 30-spline flange. Besides, it is way too strong for the stock style flange, it eats them for lunch. Seriously, we had to develop a heavy duty flange just for it (more on this later).

Noticeable comparisons...
Two notches to stake the flange nut, double insurance (stock only has 1 stake)
Huge 24mm flange nut (stock is 20mm)
The smallest diameter of the stock shaft is found between the bearing race and the gear. We carried the bearing race diameter all the way across to the shank for maximum strength. Result is a 29.2% larger diameter with 67% more material.
One-piece design for maximum strength and reliability

Now for some size comparisons...


Now for some pics...

Below is a comparison of the stock 27-spline front output (left) and our 30-spline Chromoly front output (right).
Notice how massive the 30-spline section is compared to the 27-spline section.
As mentioned above, we carried the massive bearing race diameter straight across resulting in 67% more material.



We added an extra stake to make sure the flange nut stays put.
The stock 27-spline piece really looks minuscule in comparison



And if it's massive size plus Chromoly alloy wasn't enough, we all know that no matter how well you polish the stock output, front or rear, the flange is a serious weak link. That is why we designed an oversized shaft, which of course required a larger flange.

During testing, we found that the thickness of the stock flange was insufficient. We simply have too much shaft for the flange. What's the point in using a heavy duty output shaft if you are just gonna break flanges all day long? Therefore we designed our oversized "4-30" 4-pattern 30-spline Heavy Duty flanges with a 135% thicker cross-sectional area.




This is what happened when we used a flange on our 30-spline Rear Output shaft that had the same cross-section as a 27-spline flange.
(Both our front and rear Chromoly outputs have the same exact spline dimensions.)




In conclusion...

Marlin Crawler's new 30-spline front output shaft has 67% more material where it counts, is made from Chromoly alloy, and is a 1-piece design. It uses a 135% thicker flange with an 11.9% larger spline. It comes with an EcoSeal to protect the environment. No modifications required, simply remove and replace the old components with our larger and stronger parts. And lastly, it's a Marlin Crawler!!


How/Where do I order?

The kit retails for $249, but if you act before November 14, you can take advantage of a 15% off introductory special offer! :thumbs:

Product link: http://www.marlincrawler.com/transfer-case/parts-upgrade/30-spline-chromoly-front-output-shaft

-Marlin Crawler
BigMike
« Last Edit: May 10, 2011, 02:28:22 PM by BigMike »
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BoG-ToY

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looks good mike, keep up the good work
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

BigMike [OP]

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looks good mike, keep up the good work
Thanks :thumbs:


We are now offering a FREE FRONT OUTPUT KIT GIVEAWAY over on Pirates, click here: http://pirate4x4.com/forum/showthread.php?t=931202 You have to post in the thread on PIRATES (not this thread) to be included. We will choose a winner at 4pm PST on Monday Nov 22nd.

Again, post in the thread on Pirates to be included!

Good luck!
Mike
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BoG-ToY

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I made my post,
Checked my pm's over there too
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

- Sales Employee -

freds40

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Don't forget, you have to have a Red Star to post to giveaways on Pirate.  :thumbs:
"between projects"

BoG-ToY

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does marlin NOT have a red star on pirate?
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

BoG-ToY

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well, if the givaway gets canceled over there, they can just give it to me? (although Id rather have a dual case adapter... lol
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

ninja turtle

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these things are beefy



heres looking down the 30spline flange into a stock flange.


Rocksurfer

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does marlin NOT have a red star on pirate?

No, they have a vendor star.  In order to get in on any giveaways on pirate YOU must be a red star member.
The Ghost-Rider/Ghost Runner

No matter how far you fall, the ground will always catch you

BoG-ToY

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Yeah did not catch that "to" part

Must be red/yellow star to "win" raffles on pirate?
The way I read that first one was "you must have a red star to POST to giveaways" sounds more like your saying you need it to Post a giveaway, not to win one.
Or to participate?
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

BigMike [OP]

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these things are beefy

heres looking down the 30spline flange into a stock flange.



OHHH YEAHHHH!!!!!!!
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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Online installation guide now available:

http://www.marlincrawler.com/guide/output_30sp_front.pdf
« Last Edit: Dec 08, 2010, 03:42:29 PM by BigMike »
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

zembalayan

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The guide is very polished and readable SO I know it took a good amount of effort to complete.  Excellent work!  Very Marlin Crawler! :thumbs:

ninja turtle

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 :beerchug: 
« Last Edit: Dec 09, 2010, 09:36:23 AM by no-idea »

BigMike [OP]

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Hey guys,

We no longer make the 35%/38% thicker 5-30 flange. We dropped the early first gen 8mm bolt pattern because no one would ever want to use it.

And while we were doing that, we made the wall EVEN THICKER! It's now 135% thicker! :o Here is a cross section comparison of a stock Tacoma flange:



More information on this flange can be found on it's product page here:
http://www.marlincrawler.com/transfer-case/parts-upgrade/four-pattern-30-spline-flange

Also I mirrored this comparison on the Front Output product page here:
http://www.marlincrawler.com/transfer-case/parts-upgrade/30-spline-chromoly-front-output-shaft
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BoG-ToY

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looks beefy, cool to see the bolt on upgrades that are really gonna make a difference.

I honestly enjoy seeing the changes....

MIKE, I have a question, Do you guys have a time line of things marlin has built/upgrade/changed including ideas that didnt work out. like I know you guys had the early low range gears that required the tighter detent springs and such... but  time line to see it in would be cool
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

yoshaleng

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Wow, the difference is night and day!

BigMike [OP]

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MIKE, I have a question, Do you guys have a time line of things marlin has built/upgrade/changed including ideas that didnt work out. like I know you guys had the early low range gears that required the tighter detent springs and such... but  time line to see it in would be cool
Hmmmmmmmm this is actually a pretty neat idea. I might use this on our website or in some marketing material this year :thumbs:
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BoG-ToY

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sounds good, I kinda ignore alot, But man I saw a dinosaur of a dual adapter the other day like a foot thick or so? I just wanna see what it would look like, see how far you have come...
Sand, what fun, drop pressure to 12psi, stock tires are still digging, can't afford to get stuck, 8psi, still not working. Find a place to GET OUT, air up, un-lock hubs,  WAIT whats this, hubs are UN-LOCKED already. 2wd, 8psi, stock tires, Oregon sand dunes.

BigMike [OP]

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We do have a comparison pic of the older adapters on our Understanding the Success of the Marlin Crawler page that needs to be updated to the new site theme:

MC01 (1994-5), MC03 (1995), MC05 (1995-96), MC07 (1996-current)


The MC01 was awesome because it is compatible with any shift-style transfer case :thumbs:

We still have MC01 serial #2 in Visalia. He drove it through the Round-Up last fall!
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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Updates on this...

I am finishing up a similar tech article for our Rear Chromo 30-spline output shaft, and I realized I calculated the percentages for the front output shaft backwards!

Here is what I originally calculated:


...and here are the corrected values (I rearranged the data to match the layout of the comparison image above):


What I did was I calculated the percentage difference of how much smaller the stock shaft is compared to our shaft.
What I should have done is calculated the percentage difference of how much larger our shaft is compared to the stock shaft.

In other words, I showed how much smaller the stock shaft is compared to ours instead of comparing how much larger our shaft is to the stock.

I have always known how to do this, but while calculating the rear output shaft figures, I realized I was getting different numbers than compared to similar features of the front output. I was like :screwy: I took the difference divided by our new part, instead of taking the difference divided by the original part. The later is proper for showing the % gain of a new component over an original component.

I have updated both the image and the text of my opening thread above, as well as the information on our website. I will correct the threads on other forums as well.

Sorry for the mistake! Now the numbers REALLY prove how much larger our shaft is!! :woohoo: :bowdown: :turtle:

BigMike

Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
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Things are only impossible until they are not.
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emsvitil

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Since the strength of a shaft is more dependant on the cross-section area rather than cross-section diameter you could say that each shaft has a xx% more metal....

i.e.

Shank diameter    1.48   vs    1.81    =   49.6%  more metal..............
Ed
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BigMike [OP]

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hahaha I calculated the circumference. W-O-W.

Very nice, very nice. I will get this worked in. :beerchug:
« Last Edit: May 09, 2011, 04:24:31 PM by BigMike »
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
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emsvitil

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Area is pi * r^2

I get cross section areas of   1.72 sqin and 2.573 sqin   which is 49.6%


you used d*pi^2
Ed
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22RE  W56B
31x10.50R15

BigMike [OP]

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Thanks Ed, the crazy pills earlier this morning were very tasty
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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Ok man how does that look now :o :o  :o 67% larger cross section!!!



« Last Edit: May 10, 2011, 05:44:28 PM by BigMike »
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

BigMike [OP]

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Ok, got the rear Output shaft article done *finally* sheeeesh

Clicky --> http://board.marlincrawler.com/index.php?topic=81290.0
Check out our new Rock Crawling Videos!
2016 56-speed 580:1 Tacoma Rock Crawler   
1981 36-speed 511:1 3RZ-FE Rock Crawler
1987 6-speed Supercharged 4A-GZE MR2
Instagram: @SlowestTacoma
Things are only impossible until they are not.
"The worst of both worlds, the best of neither." -abnormaltoy
"An informed question. But difficult to answer. I am what you see." -Nanaki

 
 
 
 
 

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