transfercase swap , info wanted
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Joined: Sep 1999
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From: Indiana
transfercase swap , info wanted
My Son-Inlaw has a 78 Ford F150 4x4 with the NP 203 fulltime transfercase that is starting to puke, grinding and vibrating that comes and goes when in 2 wheel drive. What pieces do we need to change to a NP 205 transfercase. I'm thinking a transfercase, both drive shafts, both differential flanges, that adapter housing between the case and transmission, and the drive sleve. The truck has the C-6 auto trans also. Is this right? How bad of job is this. I have access to the parts so thats no problem. I'm blessed to be friends with a guy that has bunches of 73 to 79 4x4's. Thanks!
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transfercase swap , info wanted
Over the years of interest here all Ford tcases used a circular bolt pattern and a 31 spline input shaft on the transmission end, so an NP205 should bolt right up. I'm not that familiar with the 203 case but I would guess that it uses the same U-joint size as other 1/2 ton cases, so you may be able to get away with shorting/lengthening the drive shafts. Since you want to go from a full time case to a part time case you'll have to convert the hubs on the front axel to manual. With the Dana 44 front axel Warn makes all the parts.
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Joined: Sep 1999
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From: Indiana
transfercase swap , info wanted
Bill, Thanks for the reply. This truck has a conversion kit in the full time case to part time. Its a pain because you have to come to a stop, shift the transmission to nuetral, then shift the transfer case. Thats what the instructions with the kit said you had to do or "major damage could occur". Lucky it already has a set of premium Warn hubs on it!
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transfercase swap , info wanted
You may well have to swap your driveshafts adapter and tranny as well .Fords usually used the short adapter on the 203 because it has the low range reduction box in front of the case .Ford C6 trannies had 6 different output shafts (at least thats how many ive got) to deal with the different case combos. A 205 case with a double cardan Cv joint on the front shaft MUST be used with the long adapter and corresponding trans shaft because of the shorter case length. Otherwise the front drive shaft WILL hit on the trans case.I am fixing this problem on a truck in my shop right now Thanx
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From: Indiana
transfercase swap , info wanted
Bill atHardcore4X4, The truck has the c-v joint set up on the front driveshaft with the full time case. On a 79 f-150 I saw with the 205 it did not have the c-v joint in the front driveshaft, it was just a u-joint on each end. So would he just be better off to find another 203? As to have to fool with the other stuff of hit and miss parts. The billfold is not large and a long down time is not wanted while trying ot figure out what fits and what doesn't fit. I just figured it would be an easy swap, find the same year donor truck with desired parts and have at it. Thanks! Let me know what you think!!
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transfercase swap , info wanted
Your cheapest and fastest route would be to find another 203. Even if you swapped the 205 directly in you would have to change the length of both driveshafts. The truck I just finished fixing had this trouble .The owner swapped in a rebuilt 205 and C6 with the short spacer and had to move the crossmember forward 6". When he tried to bolt in the driveshafts the rear was too short and the front was too long.At this point he was fed up with it and brought it too me .Because it was lifted it had to have the cv joint and he wanted too keep the 205 so I had to do a lot of work to make things work again.If you have other questions let me know.
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Posting Guru
Joined: Sep 1999
Posts: 2,297
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From: Indiana
transfercase swap , info wanted
Bill at Hardcore4x4, I have access to a salvage yard with lots of 78 and 79 F-150 4x4's. I could get whatever parts needed from one truck. I would really like to see this swapped to a NP205. My Son-inlaw and I are finding there not to be any NP203's locally. I could get the factory driveshafts, t-case, shifter, adapter, coupler, and differential flanges if needed. Would this take us all the way to a simple straight up swap?
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transfercase swap , info wanted
Hi superdave. If you have access to a complete parts truck you will need the following parts. T case , adapter ,driveshafts, transmission, t case shifter, trans mount,crossmember. With these parts the conversion will be a straight bolt in. The pinion yokes on the axles should be the same but it never hurts to check. If you can find a truck with the short adapter and a 205 that would save having to change the transmission but you wont be able to use the cv joint.If your truck is stock height and you dont plan on lifting it this will work fine. Good luck!
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