well ive been seeing alot of good info on the T-400/205 combo but im still a litte confused at a few things.

i did search and found the 205 bible that grumpy started. my question is the 205 i got from a 85 one ton it has the non syncro ( i think that's what i have or what its called ). i want to install a dodge 32 spline front ( replacing the stock 30 spline ), what needs to be swpped? do i swap all the dodge 32 spline gear cluster into the chevy or do i use the shaft with just the 32 spline output gear and swap all the odd looking syncro stuff with the coller and fork.

for those confused on what i have it starts at post #73 on page #3 http://www.pirate4x4.com/forum/showthread.php?t=653713&highlight=chevy+205+upgrade+front+yoke&page=3 notice the oil passage on the cover at the 11 O-clock position. im guessing i dont re-use the chevy cover becasue the dodge shaft looks bigger on the end. so do i use the dodge cover?

so what needs to be swapped, i did search but i cant find a specific answer, i do some what understand what im looking at in post #73 that i posted, but im uncerton for sure what needs to be done.

jason.

If it is non-syncro'd, the shaft by itself will swap in without any issues. I have even done it in the vehicle.

ok then, after searching i think its a syncro case. like i posted earlyer it has the oil passage at the 11 O-clok positon and it has a odd looking coller. its looks just like the one i posted.

so do i use all this junk including the shifter with the dodge 32 spline shaft on it or do i swap all the dodge parts including the shifter. if i didn't have this damm issue i could have it back together, like you said KWTMECH its easy enough to just do in the rig.

jason.

If it is syncro'd, you'll have to pull everything out that is related to the front, including the shift rail.Then all of the dodge stuff will swap over Another tell tale sign of a syncro'd case is the presence of a switch in the top of the case above the front shift rail where the detent ball is.

I am sure the stock case from an '85 would have the synchro front output. That is the era of automatic locking hubs.

Even the rear needle bearing is different on the synchro and the back cover plate

Hate to say it, but I would find another case. There's a bunch out there for sale right now

i was under the impression that if i had the hole case as a doner ( like the dodge ) i could swap everything over from that including the back cover and shift fork. to be honest the bolth case's were free ( dodge and the chevy ) so i will at least try to make it work.

jason.

It should be 10, 27, or 32 spline input. I don't think chevy 205's had a 30 spline input.As far as I know you should be able to swap the dodge stuff over to the chevy case.

The only hiccup I can see would be the bearing diameter on the input. 10 and 27 spline inputs have a smaller bearing than the 32, so you might have to get the chevy case bored out to fit the dodge input. I'm not sure what size bearing the dodge one used.

ya gotta change out the shift fork too.

It should be 10, 27, or 32 spline input. I don't think chevy 205's had a 30 spline input.As far as I know you should be able to swap the dodge stuff over to the chevy case.

The only hiccup I can see would be the bearing diameter on the input. 10 and 27 spline inputs have a smaller bearing than the 32, so you might have to get the chevy case bored out to fit the dodge input. I'm not sure what size bearing the dodge one used.

Try reading this post again... :shaking:

Input-output It's the same thing, only different. Whatever :flipoff2:

whoops he did say front output, didn't he? I'm working on my 205 doubler project and had input spline count on the brain.




If he wants to swap the dodge stuff into his chevy case, he'll have to swap it out to replace the the syncro auto trac junk.

i was under the impression that if i had the hole case as a doner ( like the dodge ) i could swap everything over from that including the back cover and shift fork. to be honest the bolth case's were free ( dodge and the chevy ) so i will at least try to make it work.

jason.

Oh yeah then you're good

I didn't realize you already had the other case

BTW, I found a kick-ass NP205 manual from a company called Quad 4x4

You can get it in bound form, CD or just download it to your 'puter (what I did since it was cheapest and instantaeous)

http://quad4x4.com/4x4%20Service%20Manual%20Tech%20Library.htm

well i got it back together (nothing else to when your laid off:shaking:). went together pretty easy and it was good to have a few case's kicking around, this way i had the extra parts like the back cover.

one thing i screwed up was the orintation of the shift fork, i pulled the chevy one apart and forgot to look. then i was attacking the dodge one and before i knew it i had all the parts on the floor. so of course the first time i put it back together the fork was backwards:shaking:

so i had to pop the roll pin off the shifter and disassamble the fork from the rod and turn it back. so once all the was done it went together very easly.

so now im going to do the shift rod modifaction for the front low range. so another question is when you pop the shift rails out is there a certon spot the rails need to be at. i had to use a decnet sized punch and hammer to drive them out, then i see that theres two rods holding them or locked together.
i wasn't afriad i mean its a 205 what could i brake but if theres an easyer way then lets here it. ya ya i know friggen newbe questions:flipoff2:

jason.

The "long" part of the shift fork always points forward ;)

so now im going to do the shift rod modifaction for the front low range. so another question is when you pop the shift rails out is there a certon spot the rails need to be at. i had to use a decnet sized punch and hammer to drive them out, then i see that theres two rods holding them or locked together.
i wasn't afriad i mean its a 205 what could i brake but if theres an easyer way then lets here it. ya ya i know friggen newbe questions:flipoff2:

jason.

search :flipoff2:
http://pirate4x4.com/forum/showthread.php?t=572617&highlight=cheap

search :flipoff2:
http://pirate4x4.com/forum/showthread.php?t=572617&highlight=cheap

oh i have that booked marked :flipoff2:

my question was if im removing the rails the right way. im just driving them out with a big punch. i will have it done tonight so i geuss its not big deal but i had to really hammer them out. agin its probally not hurting anything but is there a "right way" of doing it.
jason.

The "long" part of the shift fork always points forward ;)

smart ass:p

jason.

ok im a dummey i didn't relize the front output shaft rail needed to be in in the nutreul postion and the damm thing slide's right out:shaking:

ok well its done and im very happy thanks for all the help.

jason.

smart ass:p

jason.


Glad I could help :grinpimp: