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Older atlas 2 to 6r80

Hemmer

Full Member
Joined
Aug 11, 2008
Messages
215
Hello so I have a older Atlas 2. Pre 2007. You can’t purchase a shorter 31 spline shaft to convert it for the 6r80. I was told I need to cut down a long 31 spline shaft. Has anyone done this? Any tips/tricks?
Thanks
 

BUCKWILD

Full Member
Joined
Jun 20, 2016
Messages
350
Loc.
Butte county
Most likely a cuttoff wheel on a grinder will work the best havent cut that but other trans shafts. They are hardend so a saw wont work. protect everything around it cut it and clean in up well after it cools. might want to bevel the splines on the edge to clean them up and to help with alignment
 

Broncobowsher

Total hack
Joined
Jun 4, 2002
Messages
34,834
The 6R80 is still a distant dream for most, not that many actually in Broncos. I would guess less then 100 in the wild. Now asking about mating a 12 year old aftermarket transfer case to it? Pretty good odds that you are the first to even try this.

Do a bunch of measuring and test fitting, where are the limitations? If the transmission output shaft is shortened, how does this affect the transfer case input shaft and will it now bottom in the transmission case?

They do make spacer rings if you have to shim the transfer case back so it doesn't bottom inside the transmission case.
 

Cactus killer

Sponsor/Vendor
Sr. Member
Joined
Dec 22, 2005
Messages
736
Yes die grinder will work, we just did a 4R70 to a 6R80 swap out, behind a coyote we did a while back using an older atlas (2005)
You will love the 6R80 it is awesome
We are putting one behind a 347 in a Baja bronco we are building now.
 
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