Transfer case went out on my 91. Question is, do i fix the Borg Warner, or swap in a NP 205?

 

I believe that isn't a direct swap, and the BW1356 is a great, dependable unit (mine is still alive after 18 years and plenty of use). I would stick with it, either rebuild the one you have or get another one (JY, rebuilt, new, your choice).

 

If you've got access to a 205 there is no contest. The 205 has the reputation of being "bullet-proof" and with no chain to stretch (the transfer is done with all gears) and can even be modified to operate as a twin stick t-case. This gives it the capacity to operate in essentially FWD high and low, RWD high and low and 4WD high and low. The only other t-case that has that capacity AND will bolt into your truck without adapters is a brand new Atlas.

But you know, if you want to repair the 1356 and send the 205 my way I certainly won't argue with that idea either.

 

the 1356 has a lower low range then the 205. linkage, mounts will need modified more then likely as would drive shaft lengths. 1356 tcases are common and a dime a dozen. Dont get me wrong the 205 is great tcase and has its place.

how do you use your bronco? are you running large tires and things like this??

 

Guess I got a lil carried away. I've been contemplating the 205 swap for a while and since I have wide-ratio ZF the slightly higher ratio doesn't bother me. Kem is right though, the shift linkage needs mods to make it work.

 

it would rock behind a ZF since it has such lower gears similar to the NP435.

 

So, for general information because it suits the topic here...

NP205 low gear is 1.96:1
BW 1356 Low gear is 2.69:1

 

thanks Grey, i always forget what the ratio difference is between the 2.

now i have read that you can now get a lower gearset for the np205 but its not cheap. If your rig is a wheeler it may be something to consider and still be cheaper then going with an Atlas.

 

Thanks guys.I could throw in the 208 from the F150 I'm scrapping, it has a 2,, gear ratio. I've fixed the 1356 for now, time to line up some cases side by side by side, and take measurements! I bought it with 32'' BFG MTs sure it still has 3.50 gears in axle tubes. I will also add that the oil pump in the 1356 is the biggest mistake ever! Mine, after it wore through the housing, trashed the shift fork. Pieces from the fork then went through the planetary gear set! When I dumped the fluid out it shined like silver paint! I didn't reuse this case, but the next one I opened had similar problem,not as far beyond repair. Local trans shop sold me an aftermarket "upgrade" which amounts to a piece that rivets to the case, for $60. I used the outputshaft and the fixed yoke tail housing from my wounded case, because I didn't have time or $$ to redo the rear driveshaft.
The 208 gearbox looks easy to swap. What think of that?

 

Hey, Fourx, would you mind posting over length measurements when you get them? I'd like to know the length difference between the 205 and 1356 myself.

As for the 208 swap, I don't know as much about them other than that they are also chain-driven.

 

Looks like 205 will require some parts from maybe Advance Adapters.

 

As far as I know, the NP-208 and BW-1356 are very similar and are a fairly simple swap between the two (might be a few small dimensional differences). Both my Broncos have an NP-208 in them with who knows how many original miles.
I think they switched to the BW-1356 in later years or something.

NP-208: 2.61:1
BW-1356: 2.69:1

 

OK here goes. the dimensions I measured from all three t-cases. All measurements are from the front of the case to center of the fixed yokes. All 3 are 31 spline inputs.

BW1356 1990 to rear out 17 3/4" to front out -2 9/16"

NP 208f 1981 to rear out 17 1/4" to front out -2 5/8"

NP 205 1976 to rear out 12 7/16' to front out 2 5/8"

to go from a 1356 to a 205 rear shft will need to be 5 5/16" longer front will need to be 6 1/4" shorter.
to go to a 208 rear shaft will need 1/2 longer front will need 1/16" longer.

Shift linkages will need to be modified to either one and wiring harness too.
Gear ratios are 205, 1.96:1 208, 2.61:1 1356, 2.69:1

 

Would like to see the twin stick modification for the NP205. Any links? Where would I find the shifters?

 

JKW Off Road has complete kits and shift rails for the NP 205's They make kits for Ford and GM units.