All this confusion seems to have been created by Ford.
Some of the part manuals (as NumberDummy stated) only show the 205. I have an exploded view from Ford (dated Jan 75) that IS the Dana24 but does not ID it that way. (the 203 and 205 both have a large ribbed cover on the back of the front output shaft) The diagram can be found here: http://www.fordification.com/tech/im..._64-72F250.jpg
(I'm not sure if I'm allowed to post it here)
The Ford issued diagram does state that this transfer case was used in 64-5 in the F100 and 64-72 in the F250.
It looks (to me) like someone at Ford writing manuals saw
"chain drive t-case = 203"
"bronco t-case = Dana 20"
"gear drive 1-speed = Dana 21"
"gear drive 2-speed = 205"
and completely missed the Dana 24. Aftermarket suppliers rarely double-check the OEM.
this may muddy the water a bit
I have a 59 f100 that has a spicer 24. Growing up I was told that Ford made 1/2 ton trucks and 3/4 ton trucks, etc, but they also had f100 heavy half listings. I do know that the spicer 24 was delivered to my dad with the 24 in it, it has never been replaced. Anyone have any input on this transfer case linked up to a 4bt cummis approx 120 hp/300ftlb torque?
Most of the confusion is people do not seem to understand that ford did not produce these. prior to 64 they were an option installed by the dealer. Today options are factory installed. Options use to be things the dealer installed after they ordered your truck and such dealer installed options do not appear in ford part manuals.
You are partially right. Ford began building it's own 1/2 & 3/4 ton 4x4's in 1959.
Before that, they were converted by an external company (Marmon-Herrington) and sold through the dealer or a 'kit' could be purchased from Marmon-Herrington by a dealer (to be installed by the dealer). This conversion process worked much the same as it still does for ambulances, hearses, early crew cabs, schoolbusses and other special body styles. Marmon-Herrington continued building F-350 and larger 4x4's until a later date (possibly '64 ?? anybody else know?) I think they still do Ford's conversions on 3-ton and larger trucks.
Ford mechanics still had to maintain these. Unlike body conversions authorized mechanical conversions (4x4) were documented so that they could be repaired. Even as NumberDummy (THE Ford Parts God around here) has said the official books list the NP203 & NP205 as the only transfer cases used. This is simply not true. The text and pictures don't match, if you read up further you'll find a link to an exploded view dated '74 that IS a Dana/Spicer 24, but it's not labeled as Dana/Spicer part. I stand by my statement that Ford created this confusion.
ps: NumberDummy you rock !! Unfortunately, not all parts guys are created equal and some believe those parts books were chiseled on stone tablets by the infallible hand of Henry Ford himself. A parts manager near me came just short of calling me a moron because tried to get parts for this "non-existant" transfer case. ND, your efforts have helped me and many, many, MANY others get info we never would have found ourselves. And the internet preserves this info for others who will hopefully continue to fix, rebuild and play with our toys long after we're dust.
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