too tired

[toyhatsu]

I spent an hour trying to get the fill plug out of the rear case last night.  I have a FROR cross member and the hole to the fill plug is slightly off so I can't get a (impact) socket on it.  I don't have a wrench the correct size.  Tried the center punch and hammer technique also and it won't budge.  I removed the twin stick and poured the gear oil in from the top.  After reassembly the high/ low stick functions fine but the 2wd/ 4wd stick won't go into 2wd just neutral and 4wd.  I took it out and reassembled it four times and rotated the drive flanges also...still won't shift into 2wd.  The shift rails didn't move on me during disassembly and reassembly and functioned fine before I removed it.  Any thoughts?

Also, is the front xfer case stick just high/ low or is it supposed to be high/ neutral/ low...it only moves in two positions.

I have been working 10-14 hours a day and am probably just too tired

Thanks

[MidgetMike]

2wd and 4wd only has 2 positions, low and high has 3, also low and high is on the left and 2wd and 4wd is on the right. I just did my ultimate and i had the rails all wrong and kept getting confused on what which side did so I kept screwing it up I was tired too. I took mine apart a bunch of times to good luck hope to see picks.   

[Ferg]

Front stick is only two (2) positions crawler and not.

[MidgetMike]

Front stick is only two (2) positions crawler and not.

crawl box has three (3) positions, low- neutral- high 

[kyle_22r]

ya gotta remember that with a twin stick, it shifts the rails directly, whereas a factory shifter pivots, so wiggling to the right and shifting up or down is really shifting the left(hi-neutral-lo) rail.

[BigMike]

So how's the project coming? Cranked it yet? 

[toyhatsu]

Thanks everyone!

Yes I have had the 3rz running.  Got the exhaust done.  It is 2 1/4" from the header to the flow through cat to the FlowMaster and out.  I thought it might be too loud but it just sounds real healthy.  The engine takes up the whole engine bay.  I only have a couple of hours after work to work on it each night as the garage is closed on the weekend. 

Still haven't heard from the guy who was supposed to be doing the work.  He hasn't paid on his (signed six year) lease to RockWare for six months.  No one has heard from him.

I got a pretty good Christmas bonus so I am going to have RockWare fab the cable clutch linkage, weld the spring perches (check my axle centering and pinion rotation) and do a three link with Range Rover control arms and Fox shocks as struts in the front.  This will get rid of the front shackles sticking way out in the front and add clearance under the axle as the spring under won't be there anymore.

There is more wiring to be done and the whole brake system. 

I am sure that this is a first for Marlin...dual cases in a Daihatsu Rocky.  I'll post some pics in the Rig Gallery when I am done.

[FATB0Y]

good luck on the wiring

[BigMike]

Are you keeping the exhaust on the passengers side?

If not, then I am interested in some pics of how the header was modified to dive under the trans, if you went that route anyways.

Looking:

Pretty soon:

And then:

[toyhatsu]

BigMike,

I was concerned about vaporlock running the exhaust on the passenger side.  As you noted before all the fuel and brake lines run along the inside of the frame rails.  There is about three inches between the driveshaft and the flex pipe though it doesn't look like it in the pic.  I may have to do something else once it is tested on a ramp.  I got the before cat O2 sensor in and still have to get one for the after cat.