Author Topic: Transfer Case Swap  (Read 1397 times)

0 Members and 1 Guest are viewing this topic.

Offline 93Powerram

  • Newbie
  • *
  • Posts: 160
  • Gender: Male
Transfer Case Swap
« on: June 26, 2011, 02:07:13 PM »
Last night my np241 grenaded behind my nv4500. It held up well but the case failed. The tranny and t-case were 1993 w250 with gas 5.9(360) I have a 1989 gm np205 32 spline(just t-case,no adaptor off th400) im planning to put behind the 4500. My question is will the trans to t-case adapter fit the 205?(I havent pulled whats left of the 241 off the truck yet cause it will still move in 2wd)and question #2 can i just change the output shaft of the tranny and install a chevy nv4500 output shaft providing the bolt pattern will work? Is there anything else im over looking while doing this swap? Thanks in advance -Matthew-
1979 Power Wagon crew d60/d60 4.10 np435/203 warn 12000lb winch
1966 Powerwagon w200 (Hillbilly Express)wide block, np 435 np 201, braden lu2
1965 Power Wagon w 200 soon to have Cummins (Big Red Express)
1993 Powerram  slowly donating it parts to the others
2004 3500 ctd 4x4 nv5600 all stock
1973 challenger 340 rallye restored
1974 challenger resto project 

 I DONT UPGRADE IT TILL I BREAK IT

Offline Elwenil

  • Militant Parts Guy
  • Global Moderator
  • RCC Addict
  • *****
  • Posts: 22142
  • Gender: Male
  • I am the voice of reason in an unreasonable world.
Re: Transfer Case Swap
« Reply #1 on: June 26, 2011, 02:49:18 PM »
There technically is no output shaft in most manual transmissions as it is part of the mainshaft.  Some of the GM NP205s do have the right bolt pattern but I don't keep up on which ones are which.  The splines will definitely be off though it may be possible to use a Dodge input but you will have to find a way around the larger bearing that the GM input uses.  Either way unless you have your heart set on swapping to a NP205, which is a much stronger transfer case and something I would do and have done, swapping in another NP241 would be a lot easier and cheaper.

You may want to look around and see if someone will swap your GM NP205 for a Dodge NP205.  If your GM 205 is a 32 spline version it is ideal for a doubler setup and would save someone the trouble of having their Dodge NP205 machined for the GM 32 spline input.
L.Clemons

1988 Ramcharger-Mil-Spec AW450 Project-318EFI-NP435 4 speed-NP205 Transfer Case-Front & Rear Dana 60s-Braden Wormdrive Front Winch
I do not like shortcuts.  Any job worth doing is worth doing right.

Auribus Tenere Lupum

Offline 93Powerram

  • Newbie
  • *
  • Posts: 160
  • Gender: Male
Re: Transfer Case Swap
« Reply #2 on: June 26, 2011, 05:38:54 PM »
Ok,
 Elweni ,thanks for the info. I wasnt thinking.The mainshaft is the "output shaft". Im not looking for a quick fix. I am set on this t-case. Mechanical difficulty doesnt matter to me, just figuring out which pieces i can mix and match is most difficult. Just a thought about the mainshaft, maybe a mainshaft for a gm nv4500 will work?
« Last Edit: June 26, 2011, 05:48:18 PM by 93Powerram »
1979 Power Wagon crew d60/d60 4.10 np435/203 warn 12000lb winch
1966 Powerwagon w200 (Hillbilly Express)wide block, np 435 np 201, braden lu2
1965 Power Wagon w 200 soon to have Cummins (Big Red Express)
1993 Powerram  slowly donating it parts to the others
2004 3500 ctd 4x4 nv5600 all stock
1973 challenger 340 rallye restored
1974 challenger resto project 

 I DONT UPGRADE IT TILL I BREAK IT

Offline 93Powerram

  • Newbie
  • *
  • Posts: 160
  • Gender: Male
Re: Transfer Case Swap
« Reply #3 on: June 26, 2011, 06:04:30 PM »
The part listing dis. on the mainshaft for a dodge nv4500 of 17-3/4" and the gm was 19-3/4". I assume this variation in length would be on the t-case end?
1979 Power Wagon crew d60/d60 4.10 np435/203 warn 12000lb winch
1966 Powerwagon w200 (Hillbilly Express)wide block, np 435 np 201, braden lu2
1965 Power Wagon w 200 soon to have Cummins (Big Red Express)
1993 Powerram  slowly donating it parts to the others
2004 3500 ctd 4x4 nv5600 all stock
1973 challenger 340 rallye restored
1974 challenger resto project 

 I DONT UPGRADE IT TILL I BREAK IT

Offline 340SHORTY

  • Sr. Member
  • *****
  • Posts: 4098
  • Gender: Male
  • on a steep hill
Re: Transfer Case Swap
« Reply #4 on: July 3, 2011, 09:45:44 PM »
what is the spline count on your 4500?  if its a 25, get a 205 from a 89/93 Cummins truck with a automatic trans...the 205s from the Cummins truck Getrag and 4500s are the larger spline..
« Last Edit: July 3, 2011, 09:50:53 PM by 340SHORTY »
Your truck info goes here...

Offline Elwenil

  • Militant Parts Guy
  • Global Moderator
  • RCC Addict
  • *****
  • Posts: 22142
  • Gender: Male
  • I am the voice of reason in an unreasonable world.
Re: Transfer Case Swap
« Reply #5 on: July 3, 2011, 09:57:06 PM »
I think you mean 23 spline, which is the standard output spline for most Mopar 4WD transmissions.  Cummins manuals use 29 spline.
L.Clemons

1988 Ramcharger-Mil-Spec AW450 Project-318EFI-NP435 4 speed-NP205 Transfer Case-Front & Rear Dana 60s-Braden Wormdrive Front Winch
I do not like shortcuts.  Any job worth doing is worth doing right.

Auribus Tenere Lupum

Offline 340SHORTY

  • Sr. Member
  • *****
  • Posts: 4098
  • Gender: Male
  • on a steep hill
Re: Transfer Case Swap
« Reply #6 on: July 4, 2011, 05:18:47 PM »
my bad, miss type..  I agree 23 spline for the Cummins 727/205 rigs,  29 spline for the Getrag/NV4500 trucks...
Your truck info goes here...

Offline 93Powerram

  • Newbie
  • *
  • Posts: 160
  • Gender: Male
Re: Transfer Case Swap
« Reply #7 on: July 5, 2011, 08:13:27 PM »
Thanks for the info. I picked up a complete 1976 w200 with a full time t-case 23 spline. After some consideration a doubler is in the plan for this truck. My nv 4500 should be 23 spline for the gas version and the cummins is 29 spline as i understand.
1979 Power Wagon crew d60/d60 4.10 np435/203 warn 12000lb winch
1966 Powerwagon w200 (Hillbilly Express)wide block, np 435 np 201, braden lu2
1965 Power Wagon w 200 soon to have Cummins (Big Red Express)
1993 Powerram  slowly donating it parts to the others
2004 3500 ctd 4x4 nv5600 all stock
1973 challenger 340 rallye restored
1974 challenger resto project 

 I DONT UPGRADE IT TILL I BREAK IT

Offline Elwenil

  • Militant Parts Guy
  • Global Moderator
  • RCC Addict
  • *****
  • Posts: 22142
  • Gender: Male
  • I am the voice of reason in an unreasonable world.
Re: Transfer Case Swap
« Reply #8 on: July 5, 2011, 08:58:21 PM »
Just so you know, the NP203 does have 23 spline but also is an odd bolt pattern and requires an odd length to the transmission output shaft.  It is possible to mate an NP203 to a NV4500 for fulltime or doubler use but it's not going to be a simple bolt up.
L.Clemons

1988 Ramcharger-Mil-Spec AW450 Project-318EFI-NP435 4 speed-NP205 Transfer Case-Front & Rear Dana 60s-Braden Wormdrive Front Winch
I do not like shortcuts.  Any job worth doing is worth doing right.

Auribus Tenere Lupum

Offline 340SHORTY

  • Sr. Member
  • *****
  • Posts: 4098
  • Gender: Male
  • on a steep hill
Re: Transfer Case Swap
« Reply #9 on: July 5, 2011, 10:33:39 PM »
read again......slowly

the 205 from a Cummins with a 727 is a 23 spline T case...    the 205 for a  Cummins with a  Getrag or NV4500 are 29 spline....
Your truck info goes here...

Offline 93Powerram

  • Newbie
  • *
  • Posts: 160
  • Gender: Male
Re: Transfer Case Swap
« Reply #10 on: July 6, 2011, 12:17:00 AM »
read again......slowly

the 205 from a Cummins with a 727 is a 23 spline T case...    the 205 for a  Cummins with a  Getrag or NV4500 are 29 spline....

Im using a nv4500 from a 360 magnum and the np205 t-case i have is 32 spline round pattern from a chevy.I dont have any cummins parts. The full time np 203 t-case is 23 spline.

Just so you know, the NP203 does have 23 spline but also is an odd bolt pattern and requires an odd length to the transmission output shaft.  It is possible to mate an NP203 to a NV4500 for fulltime or doubler use but it's not going to be a simple bolt up.

I dont think iv ever done anything the easy way. At this point im gathering all the major components for this build .Just want to make sure that there is going to be some compatability between them. Thanks for your help and time so far. Im sure down the road ill have more questions and thoughts. ;D
1979 Power Wagon crew d60/d60 4.10 np435/203 warn 12000lb winch
1966 Powerwagon w200 (Hillbilly Express)wide block, np 435 np 201, braden lu2
1965 Power Wagon w 200 soon to have Cummins (Big Red Express)
1993 Powerram  slowly donating it parts to the others
2004 3500 ctd 4x4 nv5600 all stock
1973 challenger 340 rallye restored
1974 challenger resto project 

 I DONT UPGRADE IT TILL I BREAK IT

Offline 340SHORTY

  • Sr. Member
  • *****
  • Posts: 4098
  • Gender: Male
  • on a steep hill
Re: Transfer Case Swap
« Reply #11 on: July 6, 2011, 03:20:05 AM »
also,,,,,  a 23 to 29 or a 29 to 31 coupler doesnt exhist... 
Your truck info goes here...