I've been reading a lot of threads, but I can't find any pics. I know I need a GM style 32 spline output and tail housing in the 4500, and a 32 spline input in the 203 range box. Then, I'll need to drill and tap the face of the 203 to mount to the 4500. Seems straight forward.

But, does anyone have any detailed pics of this combo? I can't even find a pic of the GM 4wd tail housing.

Since I have a Dodge NV4500, I need to convert the output. In my searching, I have found this exploded diagram. I assume the correct tail housing is the upper Chevy one (oddly labeled "Chevy 4wd":) ), but what is the tail housing labeled "Chevy P Series"?

http://www.tbtrans.com/13400f90.jpg

The GM 4wd tail housing appears to have a 6-bolt mounting flange that is much smaller than the Dodge 4wd 6-bolt mounting flange. Is that correct? It just looks weaker in that small pic, and my aluminum Dodge tail housing didn't do that great with a heavy NP205 hanging on it:
http://rockcharger.com/trucks/75pw/pics/cswap%20048.jpg


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The "p"series is a 1-1 1/2ton box van chassis like UPS. If I may why the 203? If you are doing the doubler and have the late dodge 4500 why not use it that way with extra cross member and end up 3-4" shorter. Check out Advance Adpt for more info but you may be changing mainshafts. Six States in your area is a good source for 4500 parts and info. My $. 02

Pics of a NV4500/203/205 in here:

http://smg.photobucket.com/albums/v220/tRustyK5/?start=all

The "p"series is a 1-1 1/2ton box van chassis like UPS. If I may why the 203? If you are doing the doubler and have the late dodge 4500 why not use it that way with extra cross member and end up 3-4" shorter. Check out Advance Adpt for more info but you may be changing mainshafts. Six States in your area is a good source for 4500 parts and info. My $. 02
It's complicated, but since you asked: This is an oddball project. The NV4500 I have has a 29 spline output. The splines are severely worn (http://rockcharger.com/trucks/75pw/pics/cswap%20051.jpg) so the mainshaft needs replacement anyway. I want to mate an NP203 to it for some reason, and a 29 spline input is not available for the 203. I could go 23 spline, but since this is still going behind a Cummins, I'm going to swap to the 32 spline which is almost as big as the 29 spline. And length is not an issue.

Pics of a NV4500/203/205 in here:

http://smg.photobucket.com/albums/v220/tRustyK5/?start=all
Thanks! That is exactly what I was looking for.

The GM tail housing defenitly looks bigger than in that line drawing I posted. I noticed that you only drilled 5 of the 6 mounting holes in the 203, why? Is it too close to the edge? Is it impossible to drill all 6 at a standard clocking?

I noticed that you only drilled 5 of the 6 mounting holes in the 203, why? Is it too close to the edge? Is it impossible to drill all 6 at a standard clocking?

*I* didn't drill anything - not my pics.:p tRustyK5 takes credit for that.

It does seem as though there's not enough material to drill. Another route is to use the Ford 203 box. I've heard you only need to fudge one hole a little to make it work. Maybe somebody else can confirm that.

http://u2slow.gotdns.org:81/tcase/np203/ford203/MVC-002F.jpg

*I* didn't drill anything - not my pics.:p tRustyK5 takes credit for that.

It does seem as though there's not enough material to drill. Another route is to use the Ford 203 box. I've heard you only need to fudge one hole a little to make it work. Maybe somebody else can confirm that.

http://u2slow.gotdns.org:81/tcase/np203/ford203/MVC-002F.jpg

You can drill all 6 holes with a 20* upclock, it pulls the tcase up. if you use the NWF doubler then you can clock the 205 to any position you want. I've got a 4500-203-205 combo. If I remember right the Dodge 4500 has the same size bolt flange, but they are drilled clocked 90* from the chevy pattern.