Update:
My mom died in August :(
My dad and I still want to move forward with this swap.
Here's what I think will work:
Fixed yoke conversion:
I *THINK* that a fixed yoke conversion on the iX T-case won't be very difficult.
Cut a driveshaft off at a length to be determined (5-8" from the front flange, probably) and machine the new end of the shortened shaft to match the T-case end of the original shaft. Cut the splines in the shortened shaft such that it will go all the way into the output gear and bottom out. This will put the front output flange of the T-case just in front of the stock rubber boot. The shortened shaft is now the yoke.
The splined end of the yoke will be drilled axially and tapped for a 10 or 12mm bolt. The back end of the output gear will be drilled for clearance to the same size bolt. With the rear case half removed, the yoke will be inserted all the way into the output gear and secured with the bolt from the back.
The rear case half will have a hole drilled in it large enough to access the bolt head with a socket. A bung will be welded onto the case over this hole and a drain plug used to seal it. Once the T-case is in the car, removal of the drain plug will allow access to the bolt... The bolt and yoke can then be removed with the T-case fully assembled and installed in the vehicle, if necessary.
My mom died in August :(
My dad and I still want to move forward with this swap.
Here's what I think will work:
- S52B32
- Oil pump, pickup tube and oil pan from E53 X5 6 cylinder
- Front diff from either E53 X5 4.4i (3.64 ratio) or 6 cylinder (4.10 ratio). I need to verify that the V8 diff bolts to the I6 oil pan, but since I have both, that should be straight forward.
- Customized bellhousing: The separable bellhousing from a 4HP22 will have the transmission mounting circle cut out via EDM, and then welded back in rotated 10 degrees.
- Built 4HP22 transmission with iX case
- iX automatic transfer case with fixed yoke conversion
- Modified (probably shortened) E46 u-jointed driveshaft with adapter plates at each end to mate up to the fixed yoke conversion and E53 diffs, both of which will have 3 bolt patterns for guibos. The u-jointed driveshaft is necessary because the E53 diff is mounted further from the crankshaft centerline than the E30 diff, so the E30 driveshaft wouldn't work.
- Either current diff (4.10) or the 3.64 VC diff I just built for another project, depending on which front diff is used.
Fixed yoke conversion:
I *THINK* that a fixed yoke conversion on the iX T-case won't be very difficult.
Cut a driveshaft off at a length to be determined (5-8" from the front flange, probably) and machine the new end of the shortened shaft to match the T-case end of the original shaft. Cut the splines in the shortened shaft such that it will go all the way into the output gear and bottom out. This will put the front output flange of the T-case just in front of the stock rubber boot. The shortened shaft is now the yoke.
The splined end of the yoke will be drilled axially and tapped for a 10 or 12mm bolt. The back end of the output gear will be drilled for clearance to the same size bolt. With the rear case half removed, the yoke will be inserted all the way into the output gear and secured with the bolt from the back.
The rear case half will have a hole drilled in it large enough to access the bolt head with a socket. A bung will be welded onto the case over this hole and a drain plug used to seal it. Once the T-case is in the car, removal of the drain plug will allow access to the bolt... The bolt and yoke can then be removed with the T-case fully assembled and installed in the vehicle, if necessary.
Comment