NP205 Tech - Divorced Ford Passenger Drop....

[axisT6]

I SAS'ed my 1995 ECSB Chevy C1500. Since I didin't want to mess with my 2wd NV4500 or deal with a $$ front shaft, I decided to use a divorced transfer case.

The project started with a F250 HP D44, however I managed to acquire a GM D60 for free so plans changed accordingly.

So, I needed to make my D-drop case work with a P-drop axle. In short, this is very easy to do. The case is symmetric in regards to the input/output mountings.

I had to modify the rear output housing:



I drilled some extra holes for the oil passage since this case was going to be clocked flat and ground a little on the oil scoop.

I went ahead and ground the rails for twinstick as well. To be safe, I also swapped the rails around also.

Here is the case mounted in the crossmember. I decided that I wanted the crossmember to run under the case.



I also had to make subframes to make this work:



Here it is installed:





As you can see, the input/outputs easily swap around which enabled me to use this case with a GM axle. Also, the high portion of this case fits nicely up in the trans tunnel.

Here it is with driveshafts:

[spidr]

That looks pretty clean. Pics of the rest of the truck?

[axisT6]

I know a lot of you will disapprove of the subframe, but aside from cutting into the floor, or putting on a body lift, this was my next best option.

[axisT6]

Originally Posted by spidr

That looks pretty clean. Pics of the rest of the truck?

Here it is now with 37s (same tires as above):





Here is with the same amount of lift with some 40s I had:



The only other thing a little unique about this build is that I used a 93' dually 14FF and adapted 02' 14FF SRW disks to it.

[b454rat]

that's pretty cool. I have a divorced Ford 205, but have a HP60. If I ever need to switch, now I know how to do it rather than getting a pass drop 205. Like the truck too. The subframe doesn't hang that far down. But it's better than a body lift or cutting the floor...

[rokcrawlr1]

cool mod. That t case mount should handle some abuse!

[Corey Young]

Have you driven the truck yet? Does hi/lo/2wd work with the inputs/outputs swapped?

[axisT6]

Originally Posted by Corey Young

Have you driven the truck yet? Does hi/lo/2wd work with the inputs/outputs swapped?

Yes, the case works as expected. I will say that clocked flat, this case does not like a lot of oil. I put enough to where the oil level was just at the lower portion of the bearings (2.5 qts) and the case proceeded to give the truck a 80W90 undercoat through the vent hose. I installed the fitting for said vent hose in place of one of the plugs you knock out to access the shift fork roll pins.

I got smart and made a catch can with a drain and installed it towards the end of the vent hose, however I think the case is done spitting oil.

[Corey Young]

The factory vent hole has a baffle so no oil gets slung out by the gears.

[angryblack]

Thats good info to know..I actually passed up a ford 205 with 1350 yokes guy sold it for 50 bucks.. To me the ford case has a better mount location than the dodge case.On the dodge there doesn't seem to be enough support down low.

[geo in a K5]

Awesome work and how did you get a free Dana 60 ???!!

[trkklr77]

i dont understand how you swapped the shift rails AND ground them for twin stick.....


if you swapped the rails the detents for the interlock pills would now be on the outside facing away from the center of the case and the interlock pills.

if you flipped the rails over to make the interlocks work then the detent ntches for the balls/springs are now on the bottom of the rail not the top.....

[Stephen]

Clean. if you want to clean up the frame rails, you could always angle the ends of the crossmember up inside the frame but its not bad for most uses now.
A gm tail housing could help with the vent issue but I think the fill spec is about 1.5 qts so you might be ok with leaving it where it quit puking. you could also run the vent to a "t" let's oil drop back into the fill hole with the other leg of the "t" going to atmosphere.

[trkklr77]

i have well over 3qrts in my ord double "flat" clocking.

i welded a bung hole into the top of the pto plate and filled er up. i would even bet there is 4+ qrt in it, no mass blow out.

id say it has more to do with your grind mod and the vent tube clocking than over fill.

[axisT6]

Originally Posted by Corey Young

The factory vent hole has a baffle so no oil gets slung out by the gears.

Good to know, however after all was said and done, the factory vent was a little too close to the oil level for my comfort. That is why I installed the vent hose fitting up top.

[axisT6]

Originally Posted by trkklr77

i have well over 3qrts in my ord double "flat" clocking.

i welded a bung hole into the top of the pto plate and filled er up. i would even bet there is 4+ qrt in it, no mass blow out.

id say it has more to do with your grind mod and the vent tube clocking than over fill.

I have roughly 2 qts in there now. The clearance grinding was so the rear output housing would fit without interference from the idler gear. I don't see how clearance grinding that spot would aid in oil dispersion throught the vent at the top of the case. Could you educate me?

[axisT6]

Originally Posted by trkklr77

i dont understand how you swapped the shift rails AND ground them for twin stick.....


if you swapped the rails the detents for the interlock pills would now be on the outside facing away from the center of the case and the interlock pills.

if you flipped the rails over to make the interlocks work then the detent ntches for the balls/springs are now on the bottom of the rail not the top.....

You are correct. After typing that I thought about it for a minute and it didn't make sence. IIRC my initial thoughts were to swap the rails also but couldn't for the very reasons you stated.

[axisT6]

Originally Posted by Stephen

Clean. if you want to clean up the frame rails, you could always angle the ends of the crossmember up inside the frame but its not bad for most uses now.
A gm tail housing could help with the vent issue but I think the fill spec is about 1.5 qts so you might be ok with leaving it where it quit puking. you could also run the vent to a "t" let's oil drop back into the fill hole with the other leg of the "t" going to atmosphere.

Hmm. What would you think about putting an NPT barb fitting in place of where the cable speedo plugs in? You can see what is left of it in the pics above. I did remove the speedo gear when I rebuilt the case so essentially there is nothing inside the tail housing that could effectively sling oil, at least not like the gears do anyway.

[Marks1985]

i recently bought a ford case for my chevy and swapped the inputs and out puts but stuck on the shifter issue is there any chance you have pictures of how you made ur shifter work. would be a big help thankyou

[Grumpy_old_fart]

swap out the shift rails.

look, this isnt rocket science.

I put a ford case married to a th400 chevy, drivers drop front output... all together with a few hours of thinking. no shift linkage adjustments required.

I built my own linkage, used a couple of pieces of flat bar, and two 3/8" heim ends.

again, it isnt rocket science

[Marks1985]

May I ask what you mean swap out the shift rails ?

[segajeep]

How long did your intermediate shaft end up being?

[cumminchevy]

Originally Posted by segajeep

How long did your intermediate shaft end up being?

X2 !!!!!!!

I've got mine down to 11-1/2"