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Old 07-04-2006, 11:32 AM   #1 (permalink)
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Angry Sm465/205 or TH350/203

The problem Is Im breaking 203's all the time. I got another 203 I could put in to keep wheeling this week., But I think I'll just break It in a couple days. I got a 465 allready mated to a 205. You guy's think I should just swap It out. I would still have to get all the stuff to hook up a clutch pedal, A new clutch, and a flywheel.I like the 203's gear ratio but their too weak. The last one I broke shot the chain through the bottom of the case.
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Old 07-04-2006, 04:08 PM   #2 (permalink)
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I had the same trouble with my old 203 set up.
I think you will find that you will have a better gear ratio with the sm465 and 205 combo then you do with the automatic.
The 350 has a pretty lame first gear and the 465 is 7 to 1, much lower and will let you crawl with better control.
If you do the swap get the bell housing that is set up for Hydraulic clutch.
85 or later is the year I got it from, and you will need the pedal assembly under the dash too. the pedal set up is different from the linkage to hydaulic clutches, and nothing interchanges.
I had the linkage set up at first and when I would flex I would lose my clutch pedal.
I think you will be really happy with the clutch set up when your done. I liked my auto but the new set up kicks ass...
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Old 07-04-2006, 04:16 PM   #3 (permalink)
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the 465/205 is the only way to go, you also 3x your crawl rate. you wont notice the low range difference from a 203 to a 205, a 203 is 2.0 a 205 is 1.96.

put in the 203 till you get the stuff to hook up the 465/205.

what are you running that is breaking 203 so often, they arent bomb proof but they will take quiet a bit of abuse.
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Old 07-04-2006, 08:05 PM   #4 (permalink)
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i think that you mean a 208, cause there is no way that you are gonna break a 203 all the time or shoot a chain through the case cause its cast iron.
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Old 07-04-2006, 08:17 PM   #5 (permalink)
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Its for shure a 203 and I for shure shot the chain through the bottom of it! I was supprised when it happened. Sounded like a shotgun went off under my truck. I had the pedal to the floor when it happened so that probably helped it.
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Old 07-05-2006, 12:03 AM   #6 (permalink)
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465/205 is a great combo. i have that but with the lomax 3:1 gears and i love it. it's a sweet set up.
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Old 07-12-2006, 03:44 PM   #7 (permalink)
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I've been running a TH350/205 combo in my '77 3/4 ton for over 5 years. No problems. Well that's a lie, I forgot to put the o-ring on the coupler and I had a b!tch of a time figuring out why I kept getting ATF in the 205. Anyway, other than that it's worked out just fine. I've taken the truck through double diamond trails on a regular basis and use it to tow my 7000lb boat on a regular basis. No problems. I did the Th350/205 because my wife and I both have shot knees and couldnt push the clutch on the SM465 for too long without severe pain. I wanted to keep the 205 and found all factory parts to do it.
Here a link to my little write up on making the swap:
http://www.geocities.com/spencerhut/...trans_swap.htm

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Old 07-13-2006, 06:12 AM   #8 (permalink)
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definetly stay with the auto. its the only way to go. definetly get rid of the 203. 205's are the only way to go. there is nothing stronger. the th350 and 205 came stock mounted together. all you need is an adapter and a 27 spline input 205, or a input for a 205 that is 27 splined. i don't have a 205 that is 27 spline but i do have the input which is really easy to change. if you need better gearing swap the th350 for a 700r4. same adapter minus the spacer. i have one of those too.
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Old 07-13-2006, 08:47 AM   #9 (permalink)
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I agree, put a 205 behind the transmission you already have. You will get a stronger t-case and won't have to swap transmissions.
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Old 07-13-2006, 10:10 AM   #10 (permalink)
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I swapped to a manual and I will never go back (not in this truck anyway). I have a hydro clutch as well. I run an NP205 now but will be swapping to the Stak monster box.
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Old 07-14-2006, 10:34 PM   #11 (permalink)
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I did the auto to manual swap (i had a tendency to kill auto tranny's) I highly recommend it... the 465 has a low first gear which imo is more fun to wheel than the auto was. more fun... not easier.. I suppose its more how you drive and what you enjoy... i personally like the control of a manual... Oh and please do tell how you blew up the 203 like it was said before they can take some abuse... oh if you do decide to go 350/205 let me know... i have an adapter,input and sleeve for sale... ooooor i have a 203 for a sm 465 that i might be willing to part with.
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Old 07-16-2006, 11:08 AM   #12 (permalink)
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in my personal experience, i think the torque converter on the auto absorbs alot of driveline shock and saves parts.

the manual is more fun to drive and the low range is better though.

go 205 reguardless of what you do if you can crap 203's regularly
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Old 07-16-2006, 03:58 PM   #13 (permalink)
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i just walked in the house from doing a th350/203 to sm465/205 swap yes i made my own slave cylinder bracket i copied from a online source it took about a hour then the master cylinder a bought a howe clutch pedal from summit made a bracket from a piece of channel iron on the floor the slave cyl has to be cut to lenghth the threaded to screw into the piece on the clutch pedal i went out and played lil on the property and all works good and im loving it good luck i agree with the guy who said install the 203 tillyou get all the parts it cost a lil but it was worth it the flywhel and clutch assm. cost the most if you want a bell housing that fits make sure the the hole is 51/8 inches across or it wont go ok rambling but good luck holler at me if you run into a snag
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Old 07-16-2006, 04:34 PM   #14 (permalink)
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keep the 203 and add a 205 doubler kit behind it and get the best og both worlds. 4 to 1 low range 2 to 1 low range and twin stick the 205 for even more options. Just a thought
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Old 07-16-2006, 05:27 PM   #15 (permalink)
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Quote:
Originally Posted by tennessee rockhumper
in my personal experience, i think the torque converter on the auto absorbs alot of driveline shock and saves parts.

the manual is more fun to drive and the low range is better though.
This is too true.. When I did the Rubicon the first time I had an auto and did alot of fun stuff without any breakage of any kind. Even with the tires chewing their way up rocks and hopping the tranny absorbs alot of the shock.
The following year with the stick shift taking the same lines I had to replace the front axles in my dana 44 3 times. When you let out the clutch there is nothing to take the shock loads any more, it's transfered throughout the drive train..
But the control you gain going up and down the different obsticles and the amount of gas you use to go over everything is worth the trade
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Last edited by Home Built; 07-16-2006 at 05:33 PM.
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Old 07-16-2006, 11:03 PM   #16 (permalink)
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The same could be said about engine torque, but I doubt people here will be pulling plug wires to save their axleshafts.

I agree though, I've broken a lot of shit (and not while riding the clutch, I never do that, always with the clutch out) and I'd imagine my 465 has contributed.

That said it's easier to fix broken axles than burned up trannies, and Superior Axle and Gear has solved my axle breaking problem indefinitely.
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Old 07-20-2006, 02:20 AM   #17 (permalink)
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odin i havent forgot just getting ready fo a ride this week end i will take pics of my setup when i gert back and send them maybe it will give you some ideas it wasnt as bad as i thought it would be
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Old 08-02-2006, 06:38 AM   #18 (permalink)
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Sweet! Thanks for all the info guys!Your all are big help and I am greatfull for such awsome tech! But It looks like Ill have to my projects on hold for about 6 months! The Marine Corps decided I need to go to Iraq! Again! Kind of sucks caus I just got back from there ,and I was really getting into wheeling in AZ! At least I wont have to pay taxes. But anyways I might not be able to get on pirate very often from there. So if you dont hear from me after AUG20 you know why! Ill definately get on here evry chance I get though!
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Old 08-02-2006, 07:36 AM   #19 (permalink)
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Either something was wrong with your case or your driveline angles are messed up. A guy cracked a few 203's on and off the trail-noticed his pinion angle was too high and rear ubolts loose. His rear pinion would jump up during load-and mechanical lock the rear drivehshaft-1st thing to break was the case...worth looking at.
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