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Dana 24 rebuild?...or swap an NP205??

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Old 08-23-2012, 05:38 PM
Tomahawk2506 Tomahawk2506 is offline
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Dana 24 rebuild?...or swap an NP205??

I'm planning on performing my own rebuild on the Dana 24 tcase out of my 67 F250. Anyone done a rebuild on a 24 before? If so, is it a pain in the a##? I've read it's not too hard to swap in an NP205, which I know is a better tcase and parts are more plentiful and available. Is the swap difficult? What all is involved? Would I need to alter drive shafts or driveline angles or anything?

Any feedback would be appreciated. Thanks.
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Old 08-23-2012, 07:07 PM
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jackslater jackslater is offline
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Just finished rebuilding my Dana 24. I ordered a rebuild kit from Early Bronco Restoration Full Size Bronco Restoration Classic Ford Bronco Parts For Sale.

You will need access to a shop press to remove/install some of the bearings.

Other than that, it's a pretty straightforward and easy rebuild.

Good luck.
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Old 08-23-2012, 11:37 PM
willowbilly3 willowbilly3 is offline
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The 24 is a fine T-case. The later (divorced) 205 is just about a bolt up but uses a different type of speedo cable IIRC>
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Old 08-24-2012, 01:36 AM
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garthneddy garthneddy is offline
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Unless you really need that extra .10 gearing in low range, i would keep the dana case.
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Old 08-24-2012, 08:13 AM
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I put a 205 in my 69. Its a easy swap but I don't remember what drive shafts I used. I can measure them if you want.
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Old 08-24-2012, 10:47 AM
willowbilly3 willowbilly3 is offline
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I ran a borrowed 205 in my 69 while I was rebuilding the 24. It all bolted right up. with the exception of the speedometer.
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Old 08-24-2012, 11:03 AM
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19704X4F250 19704X4F250 is offline
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If the truck is going off road to hit the trails, a NP205 is a must have, as it is tough!
Transfer Case Basics - FORDification.com
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Old 08-24-2012, 05:59 PM
Wildcat455 Wildcat455 is offline
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C'mon Tomahawk2506

You can answer this for yourself!

How much does the rebuild kit cost for the D24?

How much will swapping in an NP205 cost?

What are your intentions for the truck?

What is your "Headache to benefit ratio"?

You are going to have to fill in the blanks. Insufficient data.

My take... (Like, what would I do based on your anemic post??) If everything else is stock, then the 'case is too.

I wouldn't upgrade to an NP205 until I had upgraded (1350) drive lines, a D60 front, 30 spline D60 rear, and at least twice the stock horsepower.

If you are looking at Bearings and seals on the D24, (stuff that comes in the kit) stick with it.

The D24 is plenty strong. It's not as good of a design as an NP205, but unless you are really going to "Build" this truck, an NP205 is not needed.

So... Either answer your own question, or give us more information relative to your intent...

19704X4F250:

Yup NP205 is a tough case. But...

He'll break the puny little u-joints in the closed knuckle front end... Or the 1310/1330 conversion joints in his drive lines... Or snapping the (I think 17 spline?) rear axles before Nuking a rebuilt D24...

JMHO... YMMV...
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