I have an Everest T-Case in route for my 5.2 V8 swap, it does appear to have internals very similar the the f150 Raptor. slightly different design than broncos.
once it arrives I'll tear down the BRONCO advanced case to see what's inside and then we'll know for sure if the mechanical connection exists.
Back in 1999 I had a Isuzu Vehicross, and it had an early version of TOD with ball ramp clutches for front axle engagement. The unit worked completely awesome for over 300,000 miles and I was able to utilize the Troopers transfer case controller module which allowed for True lockup, the original vehicross design did not have four wheel drive high LOCK per se, I was able to utilize this feature by creating a wire that applied 12 volts to the solenoid which forced the ball ramps into a position where any torque applied from the engine would instantly lock the front drive line. If you look closely at the ball ramp design it is almost impossible for the clutches to ever slip under load... the reason is because the farther the load and torque that you apply the farther down the ball ramps the balls travel and they force the clutches together with tremendous Force. My point here is is that even if there is no spline mechanical connection, the ball ramp design is strong enough to withstand extreme forces that maybe generated between the front and rear drive axles additionally because it does not have a spline connection it allows for a degree of slip, meaning that it is possible for the clutches to slip if there is no torque applied from the engine (kind of like a ratchet)... ball ramp clutches are far superior and stronger than sprag clutches that are used inside of automatic transmissions and other applications.
I still think the Broncos all-wheel drive case design uses the motor to push the splines past the clutches inner splines to a solid spline where it is actually mechanically locked.
once it arrives I'll tear down the BRONCO advanced case to see what's inside and then we'll know for sure if the mechanical connection exists.
Back in 1999 I had a Isuzu Vehicross, and it had an early version of TOD with ball ramp clutches for front axle engagement. The unit worked completely awesome for over 300,000 miles and I was able to utilize the Troopers transfer case controller module which allowed for True lockup, the original vehicross design did not have four wheel drive high LOCK per se, I was able to utilize this feature by creating a wire that applied 12 volts to the solenoid which forced the ball ramps into a position where any torque applied from the engine would instantly lock the front drive line. If you look closely at the ball ramp design it is almost impossible for the clutches to ever slip under load... the reason is because the farther the load and torque that you apply the farther down the ball ramps the balls travel and they force the clutches together with tremendous Force. My point here is is that even if there is no spline mechanical connection, the ball ramp design is strong enough to withstand extreme forces that maybe generated between the front and rear drive axles additionally because it does not have a spline connection it allows for a degree of slip, meaning that it is possible for the clutches to slip if there is no torque applied from the engine (kind of like a ratchet)... ball ramp clutches are far superior and stronger than sprag clutches that are used inside of automatic transmissions and other applications.
I still think the Broncos all-wheel drive case design uses the motor to push the splines past the clutches inner splines to a solid spline where it is actually mechanically locked.
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