STaK 4x4 Monster Box Transfer Case - 4Wheel & Off-Road Magazine

STaK 4x4 Monster Box Transfer Case - The Big 3 Fred Williams Brand Manager, Petersen’s 4Wheel & Off Road

When it comes to wheeling, options rule. There is a new player in the transfer-case aftermarket, and the new STaK 4x4 three-speed Monster Box has more options than anything else currently available. Wondering why you would need a three-speed transfer case when your stock two-speed has worked great up until now? The multiple ratios give your 4x4 the ability to explore different terrains. In the rocks, drop it into 5.44:1 low range and crawl to your hearts content. Need a little more wheelspin for the dunes or mud? Shift up into the midrange of 3.05:1. When it's time to go home you still have the standard 1:1 high range for highway speeds.

PhotosView Slideshow 131 0601 01 z+jeep unlimited+passenger side view 131 0601 03 z+stak 3 speed transfer case+case 131 0601 02 z+jeep unlimited+rear view

The STaK unit is a smart upgrade for those four-wheelers who visit a wide variety of terrain, yet still want or need to do street driving, or those who have built their truck specifically for one terrain, but now want to explore something new. It allows you to run higher axle gearing so that at highway speeds you are not spinning the engine at excessive rpm, yet still offers the control of granny gearing for slow descents and technical climbs. Having multiple gearing choices is especially useful if your 4x4's engine doesn't have a lot of power or a wide powerband since you can make up for it with torque multiplication when needed.

There is one major downfall of the Monster Box: It's a monster. Weighing 153 pounds, this beast is more than twice the weight of a stock Jeep Wrangler NP231, but with all that weight comes gears that dwarf stock Jeep parts.

So is it worth it? As this story goes to print, the Monster Box is listed at $2,800, and though it is new to the market, the folks at STaK have been testing it under their personal vehicles with great success. If you're looking for options, this is definitely one with many options inside.

PhotosView Slideshow The guys at STaK 4x4 wanted more for their own Jeeps so they took apart a Dana 300 transfer case and figured out how to improve it. The Monster Box three-speed gears (right) dwarf the 300 gears (left). The STaK gears and shafts are made of 8620 steel that has been heat-treated and carburized. Carburization involves heating the gears and adding carbon to the exterior for greater longevity and strength. Having a strong case is especially important when running such low gears, since the force is transmitted through the case to the mounting brackets. STaK uses a cast 356 aluminum case that is heat-treated to T-6 standard... ...Once the raw castings comes to their facility the STaK gang runs it through a CNC mill to give it a fully machined finish with no rough casting surface. PhotosView Slideshow Not only are the gears very large, they are also supported with axial thrust bearings between each gearset and Timken roller bearings between the gears and supporting shafts. Then there are tapered bearings where the case supports the shafts that the gears ride on. All this equates to a smooth spinning box and reduction in drag even with the big heavy gearsets. We really like the fact that the Monster box uses no gaskets or silicone, but rather O-rings to seal against leaks. This not only helps in assembly, but also allows for cleaner dis- and re-assembly down the road if you ever wanted to. Currently 23-spline inputs are offered and 32-spline outputs front and rear are standard, though other options are in the works. The Monster Box case is made of two halves with four locating dowel pins and 20 31/48-inch stainless Grade 8 bolts holding it together. The tapered bearing preloads are set with shims that are held in place with aluminum caps, which are also O-ringed and bolted in place with six 31/48-inch bolts. Also note the three shift rails that ride on bronze bushings. The final case weighs in at 153 pounds dry and is quite enormous when compared to a Jeep CJ Dana 300 (right rear) or a Jeep TJ NP231 (left). Even though the case is heavy, it is not much longer than a 300, at just 13 inches from front to back. Final specs are 9.77 inches tall and 19.12 inches wide. Plus the Monster Box is available with either driver- or passenger-side front outputs, and uses standard off-the-shelf Spicer yokes or flanges for different driveshaft joint or CV choices. The shift-rail detent balls can be supported by different rate springs to adjust how much effort is needed to shift, plus the vents are all outfitted with check valves to release or accept outside air only when pressures require it. However, the case does not have a mechanical speedometer drive, but it does have a Mopar speed sensor and four-wheel-drive light switch since many 4x4s need it in order to keep their engine ECMs happy. The STaK engineers said the hardest puzzle of this project was the shifters. The goal was three shifters that come through the stock floor openings of a Jeep, didn't rattle, and are easily shifted. The version we saw had the rear-most lever activating the rear axle in either High Neutral or Low, and the middle lever activates the same for the front axle. Then the front-most lever chooses between 3.05:1, Neutral, or 5.44:1 low ranges. We found the shifting a bit confusing and tight, but a revised system is in the works as well as possible pneumatic or solenoid shifters that wouldn't even require levers if the customer requests it. stak 3 Speed Transfer Case fork Lift Photo 9315801

Here is the biggest issue we found with the Monster Box: its sheer size. In fact, the STaK team has found that using their forklift to help install the case in a stock Jeep TJ is much easier than having two guys bench-press 150 some pounds up and onto the transmission. We're slightly concerned about all that weight hanging off the tail of an aluminum manual or automatic transmission, but there have not been any issues thus far. STaK is working on a new mounting unit to better support it. However, the case can be mounted in 25 different clocking positions in 4-degree increments for nearly any 4x4 you are building.

stak 3 Speed Transfer Case undercarraige Photo 9315804

The Monster Box fits in a Jeep just fine, and though STaK won't make any claims about its strength, it seems more in the size range of a fullsize truck NP205 rather than a 11/44-ton Jeep transfer case. When installing in a Jeep you will need to shorten the front driveshaft 2 to 4 inches and get a new rear driveshaft. Though designed with Jeeps in mind, the Monster has adapters available for nearly any transmission you would want to put it behind. We would like to put one in a monster fullsize truck with huge tires and some serious engine or a crazy all-around trail buggy. Heck, we'd even consider one for our daily driver/weekend warrior 4x4. With a case this beefy and with so many gearing choices, the options are endless.