Oz, with your truck did you have Allison reprogram the transmission at all? Or did the end result of the taller tires with the lower gears make it almost factory again?
I am sure your welder knows what he is doing, maybe you could ask him what he is doing so you can post the procedure for others to use? That mount looks great, should be rugged as can be.
My fire truck project may not be doable, at least not like I wanted to, I would essentially need to cut...
Here is a link to the T600 manual as well, I tried to attach it, but the file was too large.
https://www.dropbox.com/s/10xf4j11veqcann/T600%20AxleTech%20transfer%20case.pdf?dl=0
I think it is a good option, do you really want to use more fuel and wear out the front tires quicker? I am not sure if the military ordered them all so they have this option or not. I am interested as well, seems like a nice transfer case to use.
I think you may find that the transfer case has the option for the AWD, but is still capable of 2 wheel drive.
"Optional features include a 32.4% front / 67.6% rear proportional differential with pneumatic lock, front axle de-clutch when proportional differential is not selected as an option"
I am worried about the 1138 a bit, but people say that it is the transmission that causes the breakage, not the transfer case.
The truck I am currently looking at is an E-One crew cab pump truck, but I will be removing the fire apparatus to install a knuckle boom and dumping flatbed.
I love the build so far, a couple of questions, originally you thought the front springs would sit correctly, based on the pictures, I guess that was off just a little bit? How are you handling steering? I have a set of the narrower axles that have the higher gear ratio already, just not sure...