Redneck Rockcrawler? Serious terrain calls for serious reduction. We'll be returning soon to the Logandale NV trails system for a post-Klune evaluation. How much of a difference in performance and tractability will the "Goliath" make?
As the singer entered the Pat Chicas Vegas Garage and Lounge, the smoky room grew dim as the spotlight fell upon him. …

"Ladies and gentleman, now it's time to slow it down just a little. This one's goin' out to all the crawlers in the crowd …It's a little number I like to call, "The slow goin' blues"…

Over the roar of applause coming from the 3 or 4 off-roaders assembled to watch the carnage unfold, a little giggle could be heard from the F-150 over in the corner, it's fenders blushing a scarlet red.

Yea baby, can you dig it? Life was groovin' as the lounge lizard drifted off into his song…….


Ok, so that's probably about the most bizarre intro for a tech article you've ever read, but let's face it. How often do you see a full size rig get pumped full of enough gear reduction to choke an average jeep owner? Like we said in the initial product review on the Goliath, gear reduction isn't the exclusive domain of the crawler crowd any more. Any off-road warrior short of a desert racer can reap the benefits of greater gear reduction, especially full size rigs equipped with the NP 205.
Here's the Beef! Between the cast iron housing of the NP 205 and the billet aluminium of the Klune Extreme Underdrive, torque handling is definately not a problem. We're anticipating a "night and day" difference between this combo and the stock 203 unit.

While the 205 is a legend in the off-road world for it's seemingly boundless strength and durability, it's pathetic 1.94 to 1 low range has led many wheelers to look to less beefy options to achieve the needed reduction. In fact, we've even heard of a couple full size rigs in the Moab area that swapped in an Atlas II - an application that Advance Adapters definitely does not recommend.

With it's cast iron case, and all gear construction, the 205 can handle hideous amounts of power without doing a fair impression of a fragmentation grenade, so it's the perfect compliment for the added demands of the Goliath. Once engaged, that Klune box is sending 2.72 times the torque that the case normally sees coming off the transmission's output shaft. With power coming from 400 cubic inches, that's a lot of force to contend with.

For just about anybody, the Klune / NP205 / Detroit Locker combo would be the ultimate set up, but there's one more trick up the rockcrawling sleeve we're going to pull - Converting the x-fer case for twin stick operation.

By their nature, lockers can make tight steering in the rough nearly impossible. When torque is applied and the lockers "spool up", the truck wants to go straight, not turn. Locker aficionados have learned to adjust their driving techniques accordingly, but there's a better way to tame the locker's steering woes and add versatility in the process. A Twin Stick Conversion.

Rather than build your own, Currie enterprises builds a twin stick shifter for the Dana 300 that's readily adaptable to the NP 205, and is built to survive nuclear holocaust. Powder coated, anodized, and equipped with brass bushings, the Currie Twin Stick opens up a wealth of options in combination with the Klune-V "Goliath". If you're going to install the Klune box and an NP205, the Currie Twin Stick's price of $129.00 (at 4-Wheel Parts in Las Vegas NV) is negligible, but the benefits are enormous. And with everything on the ground and ready to go, now is the time to make it happen.
Even more gearing options Converting the 205 to twin stick operation opens up a world of opportunities when combined with the Goliath. Just be very careful when operating in 2WD / Ultra low. That's a lot of torque for one diff to handle!

For the most part, installation of the Goliath is a straightforward operation that's well within the capabilities of the average backyard toolslinger, but there are exceptions. First, you'll need a good transmission or floor jack to remove the stock transfer case (in our case, an NP 203 that is well over 500 lbs. strong), and return the 205 / Goliath to it's intended position.

Next, you'll need to modify, or replace your stock driveshafts. The relocation of the x-fer case caused by the added length of the Klune-V box requires a shorter rear, and longer front unit. There's no way around it, it's the nature of the beast. It can be a liability on a short wheelbase rig, but on a full size, it lessens the front driveline angle considerably - big plus.

Unlike many of the major modifications off-roaders undertake, adding the Klune-V box to an old war horse like the 79 F-150 is a relatively easy, if physically demanding proposition. We're talking about cast iron cases and considerable maneuvering here, so safety should be your utmost concern. In our case, we're removing a NP 203 - a case that weighs in at around 500 lbs. The replacement 205 is a more trim unit, but still tips the scales with considerable mass. In either event, you don't want one trying to bore a rather large hole through your chest. That would suck Bevis. Take the time, and the precautions necessary to ensure a safe working environment.
Additional security We recommend using the additional mount supplied by Klune - especially with a 400 CID engine and 5500+ pounds of off-road truck. Think of it as cheap insurance against shredding the factory mounts - because it is.

What you'll need

You'll need a collection of the usual suspects - Wrench and socket set (air if you got it), Electric drill and bits (to relocate x-fer case mounts), thread locking compound, Blue RTV Silicone, WD40 or other penetrating oil to pre-soak all the hardware, and enough of the properly weighted gear oil for your application. A Transmission jack is preferred if you have access to one, but a floor jack and some careful maneuvering will get the job done. Other items to have on hand are wood blocks, oil drain pans and kitty litter (to clean up the mess that "will" happen), and a pry bar.

You'll also need a hand grinder and about 3 feet of 1/2 in. bar stock to fabricate the shift linkage between the shifter and x-fer case. While there are several ways to fabricate the linkage (including the use of "Morse Cable", the bar stock is likely the easiest and least expensive to work with for the average Joe. It's also very strong, and won't be likely to "gum up" with dirt, or break on the trail.

Klune provides a very heavy duty steel mount for the "Goliath" reduction unit that can be used on it's own, or in conjunction with the relocated factory transfer case mount. We recommend using this additional mount as the twisting forces generated by the additional torque of the Klune box could easily tear the factory transmission / x-fer case mounts loose, and lead to major damage. You'll have to fabricate a crossmember for the Klune mount, but again, this is not beyond the abilities of the backyard mechanic.
Mount it wisely The cable shifter for the Goliath box comes with plenty of slack so you'll have plenty of mounting locations to choose from. Ease of access and protection from accidental engagement are your primary concerns.

Lastly, plan ahead for the location of the in-cab shifter. Klune provides a Tuthill Controls cable shifter that's compact and easy to mount with it's included bracket. The 5 foot cable is plenty long, and will leave you with a wealth of possibilities within the cab. Choose one that allows you ease of access, while offering protection from "accidental engagement".

While it won't work for every application, ORC ace photographer Fidel Gonzales had a clear vision for the ideal mounting location. With the Mastercraft "Prerunners" installed in Flashback F-150, we'll be able to secure the bracket for the cable shifter to the drivers seat mount, allowing it to hug the seat's lower contour while moving freely as the seat adjusts.

Gettin' Ready to Rock

With all the parts on hand, and the pieces ready to go, We're gearing up (well, down actually) to take our Project: "Flashback F-150" into the realm of the slow. Unfortunately due to time constraints, we're going to have to make you wait till next month to see the actual installation take place. Trust us, you won't want to miss it!
Klune Industries
www.klune.com/v
7323 Coldwater Canyon Avenue
North Hollywood, CA 91605
Tel: 818-503-8100