I'm building a ZR2 with Dana 60s F/R on 37s. If I use the stock ZR2 transfer case, it will by far be the weakest part of the driveline. An Atlas or Stak is out of my budget right now. Would a transfercase from a fullsize truck be significantly stronger than my stock one? It would be a cheap option for me, since it will bolt right up and already has the speed sensor in the tail that the computer needs. Thanks for any help!

ZR2's use a driver's drop case for the IFS center section right? You'd need to swap one out when doing a SFA anyway so... Beefiest is a NP205; and if you have a 700R4, look for a 27 spline model in the for sale section. I think they are going for a couple hundred bucks. Otherwise 208's are more common and cheaper. They have aluminum cases and crack easier on rocks; but a skid plate would take care of that.

Yes, driver's side drop, as is my D60 front. I could use the stock case (quite a few people are) but I don't consider it to be strong enough to be permanent.

I have a 205 from the 1978 F250 I got the axles from, but I'd have to get the adapter for it to bolt to the bellhousing. My truck has the NV3500 5 speed in it now, but an auto is probably in the future.