Sounds like a great project. Overspeeding is an issue, so you'll want to make sure you get a diff ratio that keeps the motor under its redline at any speed your truck will ever travel. You could probably also adapt one of those "2-speed" rear ends to the front if you want a couple of gear ranges, or even go with a full transmission. (Some Corvettes use a rear-mounted tranny, so if you're short on space up front, you could put the tranny in back and run the driveshaft up to the front diff.)
I'd avoid using a transfer case, since I've heard that they're very inefficient compared to a transmission.
It's hard to swing a large enough EV motor with regen without going to AC (more expensive), but you could then use your deceleration to charge up the batteries--even when you're running on the freeway with the gas motor.
|