Skitime, what is your twin stick in?  I need to find a Transfer case shift for a 05 XL7 case, and thought that I had read yours is in a Gen II rig, so I would be very interested in the production or fabrication of it.  Have you had the issues of oil leakage that the other home built conversions are experiencing?  Is it the design, or do those boots stop the leakage?  Was the Dana 300 conversion that hard?  (Using a CAD program raises the level a few notches above those of us that just think it is worth a try.) 
Hope that is not too many questions at once, but trying to get as much information as possible before I start my swap to XL7 drive train.

Mine twin shifter was for my 97 Geo Tracker.  I adapted the twin shifter for a Toyota to the Tracker transfer case. I have had it in for a few months with no oil leaks including a month of offroading in Moab UT and the San Juan mountains of CO. I designed the piece on the bottom in CAD then made it on a milling machine.





I am not familiar with the XL7 drivetrain to give any advice concerning it. Sorry.

The shift housing is very different, but looking inside it seems much like my 93.  Thanks for the reply.  This is something I will keep an eye on.  There is so much to build/install out there now, It seems hard to not want to make it better.  Thanks for sharing your conversion.

Quote from: cmays03 on July 17, 2009, 11:45:09 AM

this is what i'm talking about for the conversion. but I think the twin stick would be easier since I think all you have to do is bolt it on to the top but i could be wrong.

http://www.zukiworld.com/month_120103/feature_rro2wdlowkit.htm

I saw that kit but that and the twin stick require you to drop the case and split it anyway, so I'm holding off until (if and when) I decide to upgrade 4.24 gears

yeah i really like the 4.24:1 kit its pretty easy to install. just be careful when you grind out the case for clearance for the gears. there isnt much material there but its not to bad.

I have Stan's twin stick set up, Literally. I bought his actual transfer case with low range gears and twin stick aready installed. It works great, and I love it. Two wheel low, and simple in and out . You'd be lucky to get one from him if you can. If not, Rockrat's is a well built too, and he makes a lower seal/boot set that's really well done.  Skitime's is just flat sweet. That machined housing is quite nice.

so anyone know where i can buy a twin stick for my tracker?

well I decided to see if I could modify the shift fork shaft that switches it from 2wd to 4wd today. So I think I have it figured out and its made just have to get it installed in my tcase and in the tracker. Luckly I have an extra tcase for parts so I was able to modify that one so if it doesnt work then i can just replace it. so anyways what i did was took the tcase all apart and took the shift fork shaft out that controls 2wd to 4wd and cut and ground out the slot so its longer and then took the detent ball out that is in between the two shafts its right where the other two detent balls are but in between the shafts. there is a rubber plug on the side of the tcase for that ball but it will fall out when you take the shafts out anyways. so here is a few pics of the shaft that I modified.

so by what I can tell it works but still has to be trail tested. it kinda works like a twin stick. But if its in a certain spot then it wont move over to the 2wd 4wd side but all i have to do is shift the hi low side then move to the 2wd 4wd side and select what i want then it will slide to the hi low side. but like I said have to trail test it first and see what i can do to modify it to work better.

Let me share here what I had designed for a single transfer shifter before I moved onto the twin stick design.  I shared it on the English Suzuki forum a long time ago.  In England the Tracker is a Vitara and is called the Vit for short. 

The subject of 2WD in low range was touched on in another thread called "More from Mike Hagan (and others) ". In that thread there was this post.

I spend 98% of my time in 2WD while green lane driving with my m8 and it would be great to be able to do it in low ratio :mrgreen: How does one go about achieving this then :?:  Is it a big, medium or small job :?: 
Mr Watt :?: 

I think it is important enough to have its own thread.  I have learned a lot on this subject in a roundabout way.  As some of you know I tow my Vit thousands of miles behind our motorhome each year in a search of awesome offroading. Twice when I got home from a month of fun, I found I had worn out CV axle boots. Since they were new I did not understand why. This past fall I added crawler gears in my transfer case.  While I had it apart I found out something I did not realize.  When I towed my Vit behind the motorhome with the transfer case in neutral the front axles still turn.  So with the suspension lift I had the strong CV angles caused the CV boots to prematurely wear out.  So I started looking for a solution to prevent this.  When the transfer case is in neutral it is in what I call 4WD Neutral.  So I needed to come up with a way to have 2WD Neutral.  Well this whole concept turned into a lot of research and a twin stick transfer shifter kit that I developed. The twin shifter kit for the Vit is still not ready for sale and will probably sell for around $200 US if all goes well.  I have a working prototype but I am waiting for my partner to produce a part in CNC from my CAD drawings. Here is the shifter loosely fitted for a pic.  The twin boot  in the front of the transfer case is the boot for the interior and is not used at that location.



Before I describe how you can modify your tranfer case let me explain why offroaders want to be able to have 2WD low range.  If you are using any locker in the front differential other than the air ARB locker the locker causes a real problem.  Since with a locker both wheel attempt to turn at the same speed it becomes real hard to turn the steering wheel with the hubs locked.  It feels like the steering wheel is locked straight ahead with the front diff locker and you really have to strong arm the steering wheel to make a turn.  So in this situation it would be great to be able to stay in low range but disconnect the front differential.  Without a modification you have two choices. Unlock one hub or put it into 2WD high range so you can turn easily.  A twin transfer shifter simply allows you to shift the transfer case into 2WD low range from your seat. It is simple and quick.  A modified shifter rails will also let you do the same thing but you need to move your shifter around a little more but still an excellent modification and cheap if you do it yourself.

There were some 2WD drive kits from Rocky Road and others. The last I enquired nobody was currently selling these kits.  It might of changed by now, I am not sure.  These kits consist of replacement shift rails for your transfer case.  I have spent a lot of time figuring out this method before moving onto the twin shifter design.  But you can fairly easily make these modified shifter rails yourself like the post from Mr. Watt shown above is asking about.  So let me share how you do this shift rail modification.  I must apologize because I cannot find my drawing of this mod so I will attempt to describe it.  There are two shifter rails in the transfer case.  The one on the right is to shift from High to Neutral to Low.  The one on the left is to shift from 2 wheel drive to 4 wheel drive.  There is a ball between these rails that only allows one rail being able to be moved at a time. This ball has to be removed to do this mod. To remove the ball, you have to remove only one of the rails and I would suggest the H-N-L rail since this is the rail I would then modify.  If you reassemble the rails without the interlock ball in place you can manually move the rails forward and backward.  It you move the left rail into 2WD and the right rail into the low range position you have the location you need to mark the left rail for a new notch.













So basically you grind a new notch into the 2WD/4WD shift rail.  Now let me explain why I did not do this mod. Remember I needed 2WD neutral more than 2WD Low Range.  This mod would not get me there. I had come up with other notch designs that would of allowed this but it got complicated and but that time I was onto designing the twin shifter.  Anyway hope this helps explain the mod and I hope I have all the pics in the correct order and correct description.

cool its kinda what i did but I didnt make it so there was two notches just one notch it works when i put it back together but its not in the tracker so I cant tell if it will work when its running. will get that done wednesday and test it this weekend. good thing i have two tcase and spare parts.

I just took 2 stock shifters and hacked them up, put a pin thru the middle so
they pivot right and rounded the ball portion from the oval you get with the
2 hacked bits, then welded the levers on and presto, twin sticks, they work
great

Wild