i have an 82 bronco with the stock (i believe np208) transfer case the shaft on the case itself is almost stripped and i couldnt shift out of 4 low.i tightened up the shaft and got it back in to 2 hi but for how long? what im wondering is what is a stronger transfer case that i can put in there perferably a cast iron monster, and will i have to modify the shifter? hoprefully not any questions, answere's idea's , kit's let me know

 

The 208 is a tough transfer case, but the 205 is better. I installed one in my 92 F150 with a ZF 5 spd and the splines and mounting pattern was the same. I had to remove some of the case on the ZF to clear the shifter. In your truck the only shifter mod you might have to do would be to shorten the bar between the actual shifter and the pins in the t-case. I am not 100% positive that the 205 will bolt up, but that is the strongest case that ford came out with. I would suspect that you would have to modify driveshafts as well, but dont quote me one that. I needed to have mine built for lenght since I went from a 2wd to a 4x4 in this truck. Good luck.

 

Yes, the New Process 205 is a gear-driven, cast iron housing transfer case that will bolt up in place of the NP208. However, the transmission adapter/tailhousing for the 205 is slotted for the two shifter rails of the 205. There are two versions, one is longer than the other. You could use your current adapter, but will need to slot it along the side. I'm also in the process of installing a 205 on my 84 Bronco. While it originally had the NP208, the donor F-350 truck that I swapped the driveline from has a Borg Warner 13-56. Both the 208 and 13-56 are chain drive. The 208 has an aluminum housing, the 13-56 is made of magnesium. The Low gear ratio of these two is about 2.70:1, while the NP205 is only 1.70:1 (approximate numbers). Both also only weigh about 75 lbs, while the 205 weighs closer to 180 lbs. It may also be easier to find a 13-56 than a 205, so those are two options. Each of these t-cases has it's own specific shift linkage and brackets, which are also specific to the transmission they were married to. IF you have a C-6 auto like I do, you need the linkage from the C-6, as one from some manual trannies wil lbe different.

 

Thanks That Help Allot I Do Have A C 6 So Ill Go To The Junk Yard And See If I Can Find A C6 And The Linkage For A 205 Ill Probly Also Try To Get The Houding Adapter So I Dont Have To Notch Anything Thank You For You Help!!!

 

It isnt terribly hard to notch the house with a cut off wheel and the gasket to help guide you. I agree that you may find the 13-56 easier separately than the 205 since the trucks that came with the 205 are 27 years old at the youngest, 33 years old at the oldest.

 

And the low range of the 205 is 1.96:1. You could also try and get the adapter housing off of a c6 in a 78-79 style bronco. They run the c6 with the 205.

 

Yeah, I wsn't reall sure what the low ratio was on the 205, somewhere below 2:1. I also thought that some of the 205 adapters were made of cast iron, rather than aluminum, maybe someone can answer that. Another question I had is if the adapter from the NP203 would work on the 205?

One other thing I found out on the transfer case swaps. The NP205 and 208 have the shifter on the top/middle of the floor hump, while the B-W 13-56 is along the side. In the case of my 84 with a 208, I would have to cut out the driver's side of the hump to fit the 13-56 shifter. IF you go the other way, you can swap the solid hump cover for one with a hole in the center. My cover was just bolted on, but the later models like my 88s are glued from the factory with super-strong stuff that's a bear to undo. JSM84