Transmission to Transfer Case Adaptor Kit for 2WD Truck Conversion

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Solution Overview

Problem

Current two-wheel drive trucks lack the capability to distribute torque to all four wheels, limiting their four-wheel drive functionality and requiring costly and complex modifications to achieve all-wheel drive capabilities.

Innovation Solution

A transmission to transfer case adaptor kit comprising a transfer case, connector, spacer assembly, and automatic or manual transmission mounting means that converts a two-wheel drive truck into a four-wheel drive system by retrofitting a front axle and transfer case parking brake system, allowing all four wheels to receive engine torque.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a two-wheel drive truck is converted to four-wheel drive using traditional methods, then all four wheels can receive torque, but the conversion becomes costly and complex

Engineering Contradiction:

Improvefour-wheel drive capabilityVSAvoidconversion complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The conversion system is divided into separate modular components: a transfer case unit, a front differential unit, and mounting hardware. This segmentation allows the complex four-wheel drive system to be assembled from manageable parts, reducing overall conversion complexity while maintaining full four-wheel drive functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A adapter kit serves as an intermediary component that interfaces between the existing two-wheel drive transmission and the newly added transfer case and front differential assembly. This intermediary approach enables integration without requiring complete system redesign, thereby reducing conversion complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a two-wheel drive truck is converted to four-wheel drive using traditional methods, then all four wheels can receive torque, but the conversion becomes costly

Engineering Contradiction:

Improvefour-wheel drive capabilityVSAvoidconversion cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The transfer case and differential assembly is designed as a universal kit that can be adapted to multiple two-wheel drive truck models. By creating a multi-functional conversion system that works across different vehicle platforms, the per-unit conversion cost is reduced through economies of scale and standardized component design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The conversion system allows the original two-wheel drive transmission components to remain in place and be reused, while only adding the necessary four-wheel drive components (transfer case, front differential, drive shafts). This approach recovers value from existing parts and avoids the need to discard and replace the entire drivetrain system, reducing conversion costs.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS10328796B1Transmission to transfer case adpator kit

Publication Date: 2019.06.25 ROLANDO FARRADAS AS TRUSTEE OF THE ROLANDO FARRADAS LIVING TRUST DATED DECEMBER 16 2015

AI summary

A transmission to transfer case adaptor kit, having a transfer case to convert a two-wheel drive production truck to four-wheel drive enabling a drivetrain that allows all four wheels of the truck to receive torque from an engine of the truck, whereby the truck has a transmission system and is retrofitted with a front axle adaptor kit, and a transfer case parking brake system adaptor kit and support mount.