My idea was simple take the automatic transfer case (sometimes works, sometimes doesnt) and swap in a manuel transfer case. I purchased a transfer case from a guy and the case looks great for 350 included all hardware, wire harness and new dash trim. Pulled my case off ready to put the new one up and crap I discovered the output shaft on my transmission is bigger then input shaft of the manuel transfer case. I checked around and some people think I can pull the case apart and swap out the input shaft to make it work with my transmission. I checked the gear ratios in both cases are the same but was told by a transmission shop that the model number had to be the same to and they are not, there is my problem. Has anyone done this or have any advice for someone trying it. I know it can work I am just trying to not spend a crap load more money with the swap. Not to mention the poor girl is now a 10,000 pound lawn ordiment. Any help would be great Thanks Brandon

 

I have no clue........bump.

 

What model is the manual shift transfercase? Mine is a NV 271. The electric shift should be an NV 273. The nv 271 (assuming your manual shift is that) came under a number of trucks, dodge, chevy and ford. All with different spline counts on the input. However, chevies never have a fixed yoke output on the rear, and well, I dont go under dodges anyways, so I wouldnt know that one. Did the dude tell you the transfercase came out of a ford PSD?

 

Yeah he said it came out of a PSD and he thought it was th same year as mine, he even gave me the dash trim and it fit just fine. A transmission shop locally siad Ford used three different variation in shaft spines but everthing else was the same. That transmission guy said he believes I can either order the tight input shaft or change the one from the automatic to the manuel transfer case.

 

Not having done this, or having any expertice at it, I would go for it. Yank the old case appart and see if it can be done.
I have to believe that it can.
Also, find an exploded view of the case and you'll likely see what parts would have to be changed.

 

For the last two hours I ben looking for a diagram or directions on the internet for tearing downa NV 243 and NV 241 but am having no lick. I did find a website and discovered that three different input shafts ford used have the same part number and are list for all years they apply. It looks like the different input shafts were used depending if your truck has an automatic transmission.

 

If the seal #s, and case #s are the same, than the shaft has to be the same diameter.
Unless I am missing something, it should work.
I have been inside a few transfer cases (buddy has a dodge) and there is nothing very complicated in there.

 

I hope you mean nv 271, and 273. Because the 241, and 243 exist, they are from half ton drivetrain. Your new to you floor shift model, is a nv 271 correct?

 

My mistake for some reason I wrote 241 and 243 you are correct is is 271 and 273. The new case is a NV 271 the only resaon reason I havent dug into is because I am scared of it leaking when I get it back together and someone told me that there are a lot of needle bearing inside that are a pain to get back into place. I cannot validate the last I have never taken apart a case, but am very curious. I still cant find any pictures of a teardown of the case except for a borg warner case...totally different, no help.

 

Cases I have been in were all New Process. Don't recall any needle bearing problems but we have had issues with leaking after the fact. Just take your time as if you only want to do this one time.

 

Good. I have torn apart np 208s, and np 241s. With the tailshaft facing upward, you remove the rear of the case. Atleast on those two models. The needle bearings are not like the ones in the cup of a u joint, they are like the once inside our front hub bearings. For me, they are a piece of cake to do. Im not 100% sure, but if I had to guess, the truck it came out of was a stick, and yours is an auto, or vice versa. You might count the splines. If I remember right, the one behind an auto has 31 splines, and the one from behind a standard has 24 splines.

 

My truck is a stick with the auto transfer and the shaft is larger in diameter but looks like it has less teeth, not sure I may try and count the splines tommorow if Im board. I also am looking for the torque specs on the many bolts that hold the two halves of the case together.

 

Bringing back an old thread...Did you get this resolved? i want to swap the 273 out of my PS as well. Yes the spline counts are different between the auto and manual trans, were you able to swap the input shaft from your 273 into the 271?