NP 203 to 205 transfer?
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Junior User
Joined: Jul 2005
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From: Hillsboro,Oregon
NP 203 to 205 swap?
I just registered here.I am also pretty new to 4 wheelin.I have 1978 F-150.Im wondering how much work would be involved in swapping my 203 Transfer case to a 205? http://img205.imageshack.us/img205/5...f1500031rt.jpg http://img231.imageshack.us/img231/6...f1500018cp.jpg
Last edited by Torque1st; Aug 30, 2005 at 09:10 PM.
Postmaster
Joined: Apr 2003
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From: Virginia Beach
Your best bet would be to find a truck with a NP205 and grab the following:
-NP205 (duh
)
-Rear drive shaft
-Front drive shaft
-Shifter linkage
-Maybe the Tcase frame support
Going to the NP205 will mean you need to lengthen your rear drive shaft, and shorten your front drive shaft. You will need the NP205 shifter/linkage. I don't know if you will be able to reuse your existing frame support. Maybe drill new holes to move where (if) it is needed?
And don't chuck your NP203, that front range box can fetch some nice beer money
-NP205 (duh
)-Rear drive shaft
-Front drive shaft
-Shifter linkage
-Maybe the Tcase frame support
Going to the NP205 will mean you need to lengthen your rear drive shaft, and shorten your front drive shaft. You will need the NP205 shifter/linkage. I don't know if you will be able to reuse your existing frame support. Maybe drill new holes to move where (if) it is needed?
And don't chuck your NP203, that front range box can fetch some nice beer money
Postmaster
Joined: Apr 2003
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From: Virginia Beach
Whats worth something to 1 person, can be worthless to the other. Its more of a "what do you want and do you need it to do whay you want" issue. If this truck spends 95% of its time on the road, I'd put a part-time kit in it only for the reason you'll eliminate alot of wear and tear on your front end and gain some mpg. You really won't gain anything otherwise going to the NP205, unless your send BIG torque to the ground and doing some serious offroading. And even then, a stock NP203 should be able to handle it. Only disadvantage of the NP203 as I see it is the fulltime 4x4.
Conversion kit failures, last I had read were cuased by cheap kits not oiling the rear bearing (Petersons Mag). Be sure to get a good kit.
On the other hand, if you can get the parts or a parts truck for uber cheap (or cheaper than a part time conversion kit), then fix it till you break it
Conversion kit failures, last I had read were cuased by cheap kits not oiling the rear bearing (Petersons Mag). Be sure to get a good kit.
On the other hand, if you can get the parts or a parts truck for uber cheap (or cheaper than a part time conversion kit), then fix it till you break it
Last edited by Franken-Truck; Aug 5, 2005 at 08:30 PM.
Post Fiend
Joined: Mar 2005
Posts: 8,542
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From: Louisiana
I agree with Franken-Truck, I'm doing the swap very soon on mine. You'll need drive shafts the case shift linkage and you'd have to put in manule hubs. IF you go with the part time kit then make sure to get the one that replaces the inner shaft, not just the crown gears. Mine has one of the kits in it already, and I don't like it, not sure which one it is though(previous owner converted it). I have the case linkage, and I'm about to get some shafts and hopfully do the swap some time this upcoming week.
Postmaster
Joined: Apr 2003
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From: Virginia Beach
Nope! 
He has a completely different truck then your 78. He has an aluminum Tcase (BW1356) that is chain driven and wider than your NP203/205 (and weaker). The rear drive shaft is more than likely a slipyoke style, so you can't use that (yours is fixed yoke). His front drive shaft is non-Double Cardan, and different diameter than yours. The shifter setup is unique to the BW1356. About the only thing you could use from his truck in this swap would be the shifter **** For your swap, you need to stick with 79 and earlier 
He has a completely different truck then your 78. He has an aluminum Tcase (BW1356) that is chain driven and wider than your NP203/205 (and weaker). The rear drive shaft is more than likely a slipyoke style, so you can't use that (yours is fixed yoke). His front drive shaft is non-Double Cardan, and different diameter than yours. The shifter setup is unique to the BW1356. About the only thing you could use from his truck in this swap would be the shifter ****
For your swap, you need to stick with 79 and earlier
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Junior User
Joined: Jul 2005
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From: Hillsboro,Oregon
Originally Posted by Franken-Truck
About the only thing you could use from his truck in this swap would be the shifter ****
Ok,thanks again for the info.I guess I need to decide exactly what I wanna do with the truck.I paid $2500 for it with the lift and wheels already done.I miss my last truck.it was a 73 f-250 factory high-boy.It got wrecked. I kinda would like to have 2 trucks.One to really trick out and drive around town,and one to take out in the mud.All this costs lots and takes time.This is all new for me and I am just learning.But,I really appreaciate the info.
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Post Fiend
Joined: Mar 2005
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From: Louisiana
You could get a 73-79 Parts truck(F-100-F250), or find one in a junkyard and make a deal with the owner to get the linkage,shafts, and the NP205(Most 4wd trucks came with 205s in the 70s so If you find one it would prolly be that and not the 203). I am doing this on a 79 Bronco, and I found a 78 Bronco in a bone yard with no shafts, just linkage and t case. So I picked up both for $60. Right now I'm trying to get some Drive shafts for $60, so me spending a little over $100 to do the swap, it's well worth it to me.
I think the 203 is a good case and has it's own strong points, but not for me right now. Maybe when I get into alot of money I'll take the range box off and make the 203/205 doubler.
I'll try and let you know how it goes, I already had to drop my 203 to do some work on it and that's a big anough job by its self(it weighs 300 lbs). So just be prepared for that and the 205 to weigh about 200.
I think the 203 is a good case and has it's own strong points, but not for me right now. Maybe when I get into alot of money I'll take the range box off and make the 203/205 doubler.
I'll try and let you know how it goes, I already had to drop my 203 to do some work on it and that's a big anough job by its self(it weighs 300 lbs). So just be prepared for that and the 205 to weigh about 200.
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Junior User
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From: Hillsboro,Oregon
Still looking and shopping for parts.I found a 205 Transfer case for $175.(havent bought it yet) If anyone else has done this swap let me know.Thanks 
Last edited by easydoesitmikey; Aug 30, 2005 at 08:14 PM.
Post Fiend
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From: Louisiana
Ok you need the shifter linkage, the adapter plate between the tranny and transfer case, driveshafts, and you have to make sure all the yoke and u joint sizes are all the same.
I have a 79 Bronco and I got a 78 205 and they changed u joints and yokes between the 2 years, so now I'm trying to get 79 yokes and the adapter plate that goes between the tranny and 205.
I have a 79 Bronco and I got a 78 205 and they changed u joints and yokes between the 2 years, so now I'm trying to get 79 yokes and the adapter plate that goes between the tranny and 205.
Post Fiend
Joined: Mar 2005
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From: Louisiana
Originally Posted by easydoesitmikey
Still looking and shopping for parts.I found a 205 Transfer case for $175.(havent bought it yet) If anyone else has done this swap let me know.Thanks
If you check junkyards you can usually get what you need for cheap.
If you have anymore questions, just ask. I was planning on having mine swapped out by now, but I ran into some problems, like yokes, and the adapter plate(peice of alluminum wide as t case, about 4" long, and 6" tall tops.
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Junior User
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From: Hillsboro,Oregon
OK,Im not sure how long it's been sitting around.It's from a place that specializes in drive trains.I'm also going to start checking the junk yards.Sounds like finding all the parts might take some time.