4x4 Yaris

[myfirstyota]

I know we've gone over this before, but not quite like this...

I started a thread a while back about all wheel drive. We brainstormed some good ideas, but nothing really seemed feasible for cost and result. One of our biggest hurdles was sending power to the rear. Yes, there are native awd yari out there, in some markets. Yes, they can imported. Yes, its so much easier than building one.

But...

They have small engines, undesirable gear boxes and lets be real, the cost of importing one to North America wouldn't be worth it.

I have an idea of a v8 powered, AWD/4WD, solid axle beast of a yaris sitting on 31-33" tires. Imagine a yaris body on a jeep frame....but that would be too easy.

Now stay with me here guys.

Engine:
The chevrolet LS platform is a pretty nifty one. Good power in a tight package. People have shoved these engines into literally everything and jdm is no exception. They are also very easy to wire as a standalone setup with the oem ecu. Yes I know ill have to cut the firewall, and Floorplan...extensively.

Transmission and transfercase:
The go-to transmission for an LS engine in a car or light truck is GM's 4L60E. Naturally these transmissions are available in a 4x4 version allowing the installation of a transfercase directly to the transmission. There are many companies that make adapters from the 4L60E to a plethora of transfercases from other manufacturers.

After much research, I believe the NP242J is a good fit for a transfercase. It is found in jeeps from the mid 80's up till the 2000's and is known for its "select trac" option not found on other transfercases. The transfercase has 4 modes. 2wd, 4x4 full time (awd), 4x4 part time (4 hi), and 4 Low. In 4x4 full time the transfercase acts as an open diff sending 48% power to the front and the remainder to the rear. In 4x4 part time and 4 low the transfercase locks sending an equal split of power front and rear. It is also a manually shifted case which should make installing a shifter easier than making electronic shift selectors work in the yaris.

Chassis:
I would also imagine the unibody would not be up to the task of containing such a driveline so a custom framework would have to be made. I envision a framework that follows the underbody tightly, 2 frame rails front to back with crossmembers as required and attaching to the front subframe and rear axle mounts with factory fasteners.

Axles:
The 1996-9 jeep cherokee xj has a set of axles that I would deem just about right. Not too heavy, not too wide, but strong enough for the weights involved. Also there's is just about every option available for upgraded differentials, gears and axle shafts.

Suspension:
The jeep cherokee has a 4 link setup on the dana30 front axle. This wouldn't be hard to adapt to the framework with a universal 4 link kit. The rear axle leaf spring mounts would have to be removed as I think a triangulated 4 link would be a good fit for the rear. A universal kit would work well here as well.

This won't be a quick project. I actually don't plan to start it for a while. But I have started collecting parts :)