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205 Guts Swap

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SUB602

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OK. Has anyone taken the Guts out of a Ford 205 and swap them into a Chevy 205? From what i have read all 205's seem to be the same internally, its just the input shaft and case that are different. Was thinking about it if it could be done or not, and if anyone has tried it.

Just Curious!!!
 
Six years ago I rebuilt and modified my 205 to change the imput form 10 spline (for a SM465) to a 32 spline (for a TH 400). I purchased a VHS tape that showed how to correctly dissassemble, inspect, and reassemble the gears, bearings,and levers. In this video they discussed that Ford, Dodge, and GM used this transfer case and the only thing that was different was the imput connector and sometimes the front output shaft connector. The guts were identical.
 
Not all 205's have the same guts. Some of the later model GM 205's had a synchronized front output shaft so you could shift-on-the-fly. If you have one of these, you need to swap the entire front output assembly including both bearing retainers and the shift fork. I believe the application for possibly having a synchronized NP205 are 1982-1988 1 ton trucks with with automatic locking hubs but I'm not 100% sure on that.

For a typical non-synchro 205 you should only need to change the front output shaft and the bearing/seal retainer.
 
ok info is great, but what about if both brands of 205's were early model units? Basically i received a free Ford 205 out of a 78 F-250. If i got a Chevy figure 8 case and a 27 spline input shaft can i take the guts from the Ford and build my chevy 205. What years did the figure 8 Chevy 205 cases come out?
 
SUB602 said:
ok info is great, but what about if both brands of 205's were early model units? Basically i received a free Ford 205 out of a 78 F-250. If i got a Chevy figure 8 case and a 27 spline input shaft can i take the guts from the Ford and build my chevy 205. What years did the figure 8 Chevy 205 cases come out?
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If you need to buy a Chevy 205 why are you worried about swapping everything over?

The 27 spline input is a direct and easy swap, as is the front output (if you feel like upgrading to the Ford's 32 spline setup). You should be able to find a complete Chevy 205 for $100 or so and then swap the parts you need into it.
 
SUB602 said:
ok info is great, but what about if both brands of 205's were early model units? Basically i received a free Ford 205 out of a 78 F-250. If i got a Chevy figure 8 case and a 27 spline input shaft can i take the guts from the Ford and build my chevy 205. What years did the figure 8 Chevy 205 cases come out?
Click to expand...

Might be able to find some info to help you out here:

http://www.high-impact.net/transmission_and_gear/Tcase_NP205.htm

Hope this helps.
 
Its a simple swap set up a clean space and take your time while you are in there twinstick it.
 
Most Chevy 205's in my area are running $250 or more so i was just looking at options since i had the Ford 205 sitting around. I was mainly just curious about the major differences in the 205 t-cases from brand to brand besides cases and input shafts.
 
My 1981 Chevy 205 is figure 8 and non synro ( very non synro ). I am just guessing but I bet the syncro 205's were were for suburbans with auto locking hubs probably 85 and later.
 
My 88 crewcab with manual hubs was synchronized(454/th400/205). 2 hi to 4 hi with a tap on the shifter and back just as easy.
 
I don't even know if my 205 is synchronized, I've got the same setup as desertrat in above post. And how do I know if the ford 205 has the syncro or not? Shift on the fly is really cool.
 
desertrat67 said:
My 88 crewcab with manual hubs was synchronized(454/th400/205). 2 hi to 4 hi with a tap on the shifter and back just as easy.
Click to expand...

2 hi to 4 hi should always be an easy shift as long as the hubs are locked in.

The synchro'd 205 allowed you to switch between 4hi and 4lo while the truck is moving.
 
OK so as long as the chevy 205 is non-Synchro then the swap should work? Seems easier to just pick up a complete Chevy 205. Which is the route i will most likely take, But i think i will gut the Ford and keep the parts i could use.
 
SUB602 said:
OK so as long as the chevy 205 is non-Synchro then the swap should work? Seems easier to just pick up a complete Chevy 205. Which is the route i will most likely take, But i think i will gut the Ford and keep the parts i could use.
Click to expand...

That's exactly what a lot of us do (myself included).
 
I have a round bolt pattern 205 from 85 and Im not sure its syncro or not. But if they only came with 1tons with auto locking hubs ive never seen a chevy dana 60 with auto hubs. Is there such a thing?
 
mrdrinksalil said:
I have a round bolt pattern 205 from 85 and Im not sure its syncro or not. But if they only came with 1tons with auto locking hubs ive never seen a chevy dana 60 with auto hubs. Is there such a thing?
Click to expand...

There are certainly lots of full time hubs out there (also called drive flanges or slugs) but as I said before, I've never seen auto hubs on a D60.
 
you can do that, but there is no mounting bosses on a chevy case to mount it divorce style without getting super creative. Id get a dodge case if i was looking for the divorced route, there already a pass drop case that uses 32 spline inputs and outputs.
 
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