Alright, so it does appear that you have a 203. The two linkages that attach to the "u" or "j" shaped and flat levers on the case are a dead giveaway.
Now, if the PO has installed a part time conversion, it would explain why the front driveshaft can be removed. Actually back in the day, some owners would convert the case and not install lockiinh hubs,, they would just pull the driveshaft. Saved money this way.
At any rate, you could try to turn the front t-case output without a driveshaft and see if you can turn it. If you can you have a part time kit.

 

Chuck, don't worry about the thread, it doesn't bother me at all. I'm glad to help out anyone if possible.

It does sound like you have a 203 given the pattern on the shifter (I know exactly what you mean by the goofy pattern, that is what mine has as well). It doesn't make any sense at all why someone would convert to part-time without installing lockout hubs though, that seems counter-intuitive. Maybe the case is staying in 4loc? That could explain why you are having problems with the front axle?

As 75350 mentioned, Ford also installed 205 cases in the highboys that were divorced. My dad bought a '76 F250 brand new with the parttime NP205 case, but it also came with full-time hubs. That lasted for a few months before he installed lock-out hubs to help save gas. Wish he would've kept that truck, he sold it in 2000.

 

Yea that's kinda what I'm guessing. I don't think it's shifting into HI. It's hopefully just out of adjustment and not something like a broken fork.

 

Finally got some pics to update the thread a little. Here is the problem that started all of this work, busted spring cup:


I started by stripping the spindles off of the 1/2 ton axle and dry-fitted the 3/4 ton parts to make sure the axleshafts would work. There was a question earlier in the thread as to whether or not the axleshafts were the right length, but everything bolted up without a problem. Here is the spindle and hub installed with the 36 on there for clearance checking.


Here is the axle as it sits currently: fully assembled with 4.10s and 3/4 ton outers. Also put new rotors, reman calipers, and new hoses on it. I hope this thing stops now! It barely stopped before...


This is how the truck sits right now, waiting for JBG to ship the front springs (2+ weeks right now). I got bored one night and was tired of looking at the chipped and peeling paint on the hoodscoop, so I pulled it off and repainted it satin black. I also taped off the center of the hood and painted it to match, kinda like the old Boss 302 Mustangs. I think it makes the hoodscoop look like it belongs. Now if the rest of the truck matched... soon.


Yes, that is a rust hole in the hood. I'll fix that up (fill it with Duraglass) when I paint the rest of the truck, unless I can find a better hood for cheap in the meantime.

 

Looks good!

Not to burst your bubble or anything, but it won't stop any better with those calipers. You need a better booster and master cylinder. It will probably be worse for you since your marginal setup now has more caliper to try and operate.

I will tell you that with a fully upgraded system, it will lock up the 36s.

Not the best pic, but you need a setup that looks like this


I can't tell you part numbers because the 74 has a straight thru push rod, but the newer ones have a linkage. Maybe PM numberdummy. I am sure he would know what the part # is for a 78. Tell him you need the 350 booster.

 

Ted, thanks for the tip. I want to make this work better, so I'll do what it takes to make it work. What are you running right now? '74 F350 booster and MC? I have access to a '77 F350 at the local bone yard, I could go pull the parts off of it if that will help braking power.

 

No, mine is stock. I think it was optional for 250s and the only part for 350s (but I don't know that for sure)

The big thing is that you take a look. The heavier MC has ports on the driver's side, and the booster is smaller around, but thicker.

Don't know if a 77 will work or not-you will just have to look and see. On the other hand, if you get the brackets and all, it should bolt up.

 

Oh, I forgot that your truck started as a 3/4 ton, I was thinking that you started with a half-ton like mine. Thanks for the help, I'll see what I can dig up as far as 3/4 ton or 1-ton hardware.

 

Just another update on this project for anyone who may be following along. Front end is done, currently cleaning up the rearend for the install. Rear is getting all new brake lines and wheel cylinders as well as new wheel seals and a coat of paint before going in. Christmas vacation (2weeks) starts this Friday, so the rear swap is starting on Saturday.

Drove the truck a little around the farm (ratios are different, so the NP203 is taking up the difference) just to test out the brakes. All I can say so far is that they are 100% improved. From ~20-30 mph on the road, it HOWLS the 36's with minimum input. I am very please so far. More extended road test will follow once the rear is in. This is still with the stock F150 MC/booster. I will upgrade to heavy duty stuff at some point, but I think this will work just fine in the meantime.

Here are some pics after I got the front done. The front needs aligned badly, and the stock '77 steering sucks, but it will work for now until I build a new setup. One step at a time...







The hybrid 3-4 inches of lift in the front (2" dropped coil mounts, 1-2" lift springs) nailed the stance perfectly. The rear is already lifted by the PO with 2 extra leafs per pack, and another 1" of stacked metal plates on top of the blocks. The stacked plates and factory blocks will be replaced with a single lift block while it is apart.

 

Looking good! I am surprised that the stock MC works well. Your build is so similar to mine that it is creepy. Mine is titled different, but most of the parts are the same as yours.

I remedied the stock 77 steering with GM parts. I did a writeup in the offroad tech folder, and have a gallery of my stuff. Could help you, if you go that route.

Where in PA are you? I grew up in that region.

 

Ted,

I was thinking the same thing when I saw your truck with the 3" lift, 36" Goodyears, and coil spring 3/4 ton hybrid. I didn't really plan this out, I got the truck at a good price from a buddy that needed money, and had the 3/4 ton axles and the 36s laying around, so I just put all the parts together. Our wheels are even pretty similar in design, although I like yours better. The goal of this truck is really to be just a low budget beater/off road/mud/hauling truck to save some wear and tear on my 05 F150. So far I have less than a grand in it total. I have a 460/4spd/NP205 in the garage waiting to go in, and after that happens it may also see some time at the local truck pulls that have recently started up. I don't plan on being competitive, just another way to beat on it some more .

Thanks for the offer on the steering, if you look earlier in the thread, we talked about your Chev 1 ton steering setup, which I plan to do soon. Just gotta wait til after the holidays and the cash flow gets better. I'm trying to make this thing as strong as I can for as little dough as possible, I just gotta take it a little at a time.

I think given the small bore of the F150 MC, and the large piston calipers, it really makes for a powerful system. More testing is needed to make sure I don't run out of piston travel though. This thing stops HARD though in the little testing that I did. Good enough for now.

BTW, I live in Sarver, Pa, about 40 mins north of Pittsburgh on rt28. I'm about 10 minutes from Lernerville Speedway if you know where that is. Where did you grow up?

 

A grand? I wish I only had that in mine.

Yeah, after I posted about the steering, I was looking back, and we already talked about it. Sorry for the repost.

It is interesting your brakes work well. I would think you would have run out of pedal travel because of the volume required.

I grew up in a place called Randolph NY. It is just north of Warren PA. However, most of my family lives in the New Bethlehem, Belknap, Dayton area. Also have a cousin in Kittanning. In some ways, I miss that part of the country.

 

The pedal travel is the one thing that still worries me, that will take a little more testing to see if that is a problem. I still want to upgrade to be safe, but hopefully this will work for a while. And don't worry, your truck is still WAY nicer than mine any day, so don't feel bad about having more money in it. I can stick my foot through the holes in my floor, and the 351 only runs on 6 cylinders (but runs good despite that). I still have a lot of work ahead of me, but I'm taking it one step at a time and trying to keep it drivable at the same time.

That's cool that you have family in New Bethlehem, small world! We used to haul pigs to the auction in Belnap back when my uncle was raising them on his farm. We are also regulars at the truck pull at the Dayton fairground, so I get up that way often. My fiance' lives in Kittanning. I'm only ten mins south of there.

 

My brakes only use about the top 3/4" of travel. I used all new hard lines and braided SS lines. I bled it really well, and it is firm. I have never owned a vehicle that is so firm. It isn't touchy in any way, but I would probably be picking dash out of my teeth if I 2 footed it to the floor. It really is a nice problem to have.

I spend a lot of time near Belknap when I was a kid. My grandparents and my uncle have a bunch of adjoining land near there for coal mining and farming. I can't remember all the road names, but I could still navigate the backroads there. Pretty cool area in a rural way.

 

Just wanted to give a final update on this thread. I finished up the 3/4 ton 4.10 axles conversion on my '77 a week or so ago, finally got around to snapping some photos of it today. Been beating this thing all week to work out the bugs and everything is good to go so far. Tires do awesome offroad, and the thing flexes surprising well considering it still has the radius arm front and 7-leaf packs in the rear. On the list for upgrades are steering (its horrible right now, lots of bumpsteer) and a drop bracket for the track bar, but its driveable for now. Brakes work AWESOME, locks the 36's up with very little effort. No problems with pedal travel for now. I thought I was going to have a major issue with the brakes right after I got the rear installed, as I had to 2-pump it just to slow down, but then I realized that I never adjusted the rear brakes after I put them on. After setting them up, everything works great. Now for the pics.











The color of the passenger side door will eventually be the color of the entire truck. It is Oxford Blue satin rattle can from Krylon that I picked up from Walmart. Cheap, hides a lot of imperfections, and is easy to touch up if I scratch it.

Next step for this thing will be the drivetrain swap. I got a 460/4spd/NP205 for free from a good friend of mine, and I just picked up a parts truck with a good 351w/4spd that I will be scavenging the clutch pedal and linkage from, as well as the front fenders, doors, and trans crossmember. After I get the parts that I need off of it, I am trading the 351w in it for a good rust-free cab that will be going on my 77. I was going to just patch up the floors and rockers on mine, but the chance at a rust-free cab (from the first truck I ever owned, ironically) is too good to pass up. Will be starting a new thread with pics on the drivetrain/cab swap soon, but I need to get the motor reassembled and reinstalled in my '79 2wd before I tear this thing back apart.

Btw, thanks a ton to all of you who contributed to this thread. This truck has progressed well to this point, and I owe a lot to the help and expertise that you guys have provided on here. It is greatly appreciated!