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Advanced Fabrication and Engineering For when your build is going off the charts. Wildly modified vehicles and straight up buggies welcome.

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  #16  
Old February 26th, 2007, 18:43
jmop jmop is offline
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Re: My NP435/203/205 swap

I used these sites when I rebuilt my 205 and did the twin sticks

http://www.okcnetworks.com/bronco/205/np1.htm
http://www.nitpik.com/dan/truck/spec...sfer_case.html
http://www.clubfte.com/users/ivanribic/page2.html

The first link is a step by step tear down and build up of the 205, the second is an exploded diagram of the 205 and the 3rd showes how to do the twin stick.

When I did mine I ground the rails like shown in the pictures and didn't take nearly enough off. That's a good thing though I guess. Its quite a bit harder to put it back on.

Anyways. I found that it was easier to put the shift rail pins back in and look through the holes where the detent balls and springs would go. With a flashlight you can see the detents and by moving the rails back and forth you can get a good feel for how much you need to take off. I'd still recomend taking off a little at at a time. It is easy to go past perfect and get to a point where the transfercase almost goes into high and low at the same time.

I really like how it turned out though. It is cool being able to do front digs and 2wd low.
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  #17  
Old March 1st, 2007, 12:04
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ashmanjeepxj ashmanjeepxj is offline
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Re: My NP435/203/205 swap

Nice and short setup...

Doing front digs is fun... but gets expensive...
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  #18  
Old March 1st, 2007, 12:47
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87manche 87manche is offline
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Re: My NP435/203/205 swap

Quote:
Originally Posted by ashmanjeepxj
Nice and short setup...

Doing front digs is fun... but gets expensive...
wow
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  #19  
Old March 1st, 2007, 12:58
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Re: My NP435/203/205 swap

Quote:
Originally Posted by 87manche
wow
Yea and I just cut a big hole in my floor for the 203 to mate up to the aw-4.
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  #20  
Old March 1st, 2007, 19:39
jmop jmop is offline
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Re: My NP435/203/205 swap

Quote:
Originally Posted by ashmanjeepxj
Nice and short setup...

Doing front digs is fun... but gets expensive...
Thanks. I've read your build up on PBB a couple times. Thats some nice work.

I might have to copy your design for your front 4 link. I really liked how that turned out. I need to get rid fo the rear leafs before I tackle the front again though.
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  #21  
Old March 1st, 2007, 20:21
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Capt. Nemo Capt. Nemo is offline
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Thumbs up Re: My NP435/203/205 swap

Very nice write-up and nice job on the clean up with the drivetrain components. Clean is where it's at...

This section has been severely cluttered lately with not so advanced fab questions and threads and I've been really disappointed. This was an excellent boost to this section of the board!
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  #22  
Old March 2nd, 2007, 06:53
NXJ NXJ is offline
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Re: My NP435/203/205 swap

Captain hit the nail on the head!

Any ballpark figures on how much weight this setup adds?
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  #23  
Old March 2nd, 2007, 07:23
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Re: My NP435/203/205 swap

The 203/205 will probaly weigh in at 200 to 250 alone. Not sure on the 465 but I'd guess another 200 there. Anyone knw what the aw-4 and tcase together weigh? I'd guess it added 300+ to the rig but the benifits of a bullitproof drivetrain and the bonus of the different combanations of ranges and front digs are worth it IMHO if you do it yourself and don't pay top dollar for the parts. I have about $800 in my 203/205 cases and doubler kit. You cannot even touch a klune or atlas for that.
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Last edited by Ghost; March 2nd, 2007 at 07:31.
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  #24  
Old March 2nd, 2007, 08:25
jmop jmop is offline
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Re: My NP435/203/205 swap

From the numbers I've been able to find on the web the 205 is about 130 lbs, the 203 range box is 80 lbs and the NP435 is 140 lbs. Add 20 lbs for adapters and it comes out to about 370 lbs.

I haven't found any numbers on the AW4 & 231 though, if anyone knows I wouldn't mind knowing how much heavier the drivetrain got.

As Ghost said though it is pritty much bullet proof.

Putting an atlas behind the AW4 would have ended up being slightly cheaper in my case. I got the tranny and cases for very little but the small parts and the clutch parts really added up fast. It was almost $1000 for the rebuilds, bellhousing clutch parts, master & slave cylinders and flywheel.

But one of the big reasons I did the swap, was my AW4 needed rebuilt, as it was slipping pritty bad. I had to do most everthing in 4low. Plus my XJ is an 89 so I had the 21 spline output.

Now, if I ever decide to upgrade I can get an Atlas or Stak with the 31 spline Ford transfer case mount and bolt it up and I'm still 31/32 spline all the way through.
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  #25  
Old March 2nd, 2007, 08:39
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Re: My NP435/203/205 swap

The 231 is arround 75 to 80 lbs Ihave shipped them and IIRC that is what they weigh. As for the AW-4 I have no idea but I'd bet it would weigh 100 easy. I stand by my gueses, the 203/205 will weigh 250. I guessed wrong on the tranny though. I would have thought that thing with bellhousing and all would be 200 easy. I test fit the 203 behind the aw-4 yesterday and it fit great. I'll try and find my camera over the weekend and start a thread and stop mucking up your perty one.
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  #26  
Old April 2nd, 2019, 16:50
Newbewdyxj95 Newbewdyxj95 is offline
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Re: My NP435/203/205 swap

I realize this post is 12 years old. But does anyone have pics of their set up? I found this on the web and I was wondering if it could solve the heater core issue?
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  #27  
Old April 2nd, 2019, 16:50
Newbewdyxj95 Newbewdyxj95 is offline
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Re: My NP435/203/205 swap

https://www.google.com/search?q=np43...oGY0VlodrcZi6M
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