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Old 02/13/19, 03:40 PM   #1
Full Member
Joined: Aug 08
Posts: 213
Older atlas 2 to 6r80

Hello so I have a older Atlas 2. Pre 2007. You canít 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?
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Old 02/13/19, 05:33 PM   #2
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Joined: Jun 16
Posts: 113
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

66 F/W 60'S LOCKED UP 331 EXPLORER C6 203/205
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Old 02/13/19, 05:53 PM   #3
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Maricopa, AZ
Joined: Jun 02
Posts: 29,942
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.

"She's built like a steakhouse but she handles like a bistro"-Zapp Brannigan
Why do people keep expecting "normal" from me?
Full throttle, it either solves the problem or ends the suspense.
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Old 02/13/19, 06:22 PM   #4
Cactus killer
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Just because it works dosn't make it right Jason BC Broncos

Joined: Dec 05
Posts: 632
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.

Jason BC Broncos
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Old 02/14/19, 09:55 AM   #5
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Morgan Hill, Ca
Joined: Jun 02
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Did you have any clearance issues with the Atlas and the frame? Are you running the Duff long arms?

1969, EFI HO 302, auto, cold duck, high angle drive line, E-brake on driveshaft, 35 spline full floater 9", champion beadlocks w/35" BFG'S, 7" total lift. Custom paint & many one off mods.
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