I've been reading....I have a idea, and it might work....
Bear with me here haha
Our stock transfer case is an NP233C with 27 spline input, 32 spline output, and a 4 gear planetary. An np231c will swap in place of the np233c.
Np241c and np243c came in full size Chevy trucks. They came in 27 or 32 spline input, 32 spline output, and a 6 gear planetary. The planetaries are swappable into the smaller cases (ie, np233c). The planetaries have a different cut on the gears depending on what year, new style versus old style. Input gears are swappable.
There is a rare version of the np231c with 27 spline rear output. It would be ideal for what I have in mind...
So I found this:http://naxja.org/forum/showthread.php?t=68223
The tech is basically the same, just different transfer cases (np207).
My thinking is....
S10 np231c, cut it in half, get some aluminum plate, take off the tail housing, fab up the "adapter" for np233c (just like in the link), cut off the end of the shaft to fit. This case will be the high low box, and *should have a neutral (I don't know np231c shift pattern).
Stock np233c that is in the truck (or whatever np2xx case you want) would need a 32 spline input swapped in, preferably with a 6 gear planetary with the correct cut (new vs. old cut).
What this essentially would accomplish is a level for H, N, L, which can be put in an s truck with stock interior parts. The np233c would still work with the push buttons as it is stock, all I can see needing to do is lengthen wires and breather hoses.
Other things you can do to the np233c is swap in the front output from a jeep or dodge or early s10 np231. You can also get a slip yoke eliminator (sye). Our transfer cases should have the wide chain already.
Now, what I do not know is if the 32 spline output from the transfer case will slip into a 32 spline input. This jargon is all dependent on that 1 key detail. According to the above link, we *should be able to do this easily with the 27 spline rear output, but it's rare.
If all this isn't enough options, there is an adapter to put the full size Chevy cases behind our transmissions, and we can even make an np243c work with our push buttons.
In theory, with enough room, you could run as many transfer cases as you want. Our wheelbase is long enough we should be able to get away with 2 easily.
I've been thinking about this all day....lol. I am going to try to find some parts and see what I can come up with, but it won't be anytime soon. I'd love to get something like this figured out before I swap my axles.
Here's some math:
1st x low range x gear ratio
Stock crawl ratio with 3.42 gears= 28.46
Stock crawl ratio with 3.73 gears= 31.04
1st gear x low range x low range x gear ratio
Crawl ratio with 4l60e (3.059 1st gear), 231/233 doubler (2.72x2.72), and 4.10 gears= 92.79
Please give me some thoughts on all this. There are also doubler kits available to make mating the 2 transfer cases together easier and shorter (just about any combo imaginable is doable), but I'd like to do something a little more, uh, budget....