241/205 and 203/205 comparison

[454Sub]

I know the obvious gearing and weight differences, so before someone goes into that area I have that part under control.

What I am curious about is the overall ease of doing and ease of parts gathering. I have a 241, I have the th400 205 with short input and fixed yolk VSS output with 32 spine both ends and ORD twin stick adoption, I have a 31 spline 205 Ford input as well. I have the 203 minus the 32 spline input, I have the th400 to 203 adapter. To finish the 203/205 all I need is the aluminum adapter which I can now mill my own and the intermediate shaft which ORD sells.

I can TIG weld no problem, so welding the 241 case isnt a big deal, but would it be easier to just finish the 203/205 vs finding an adapter and whatever else is needed to do the 241/205?

I know this may be just drunk rambling, but I discovered a large growth in my bank accoutn and had to celebrate and start the weekend early.

 

[Hogback Fabrication]

What transmission?

 

[454Sub]

Well thats a toss up as well. Currently its a TBI 01 454 roller with a TH400 behind it. Problem is I have the entire harness to run a 4L80E and the tranny kicking around in the garage next to this pile of mess of t-cases and adapters and parts and 10-High bottles and my kids bikes and whoknows what else.

Back on point, I would love to run the 80E, but it needs redone and I dont feel like going through a boob job to crawl when I have a beautiful th400 and it doesnt see much highway time. So basically I am leaving this up to someones idea, as at this moment I cant decide which pants to wear to work in the AM, so I am well beyond making a decision that ranks at the level of Death do us Part.

 

[Hogback Fabrication]

For your situation:

203/205 will be easy and work well. That option is heavier and the low ranges are the same, so only 3 ranges total. For most, it's still awesome compared to a single case.

241/205 has appeal because it's a 4 speed and it's lighter. With a 32 spline connection (or less) between the 241 and 205, that's guaranteed to be the weak link with 32 spline outputs. That, and the stock/welded aluminum housing are the potential weak points. Good mounts are the key but that's an art in anything but a full-on buggy.

203/205 is generally WAY easier. Easy factory mounting combinations.

The "available" 241/205 "kits" are generally not machined to center the input/output shafts, so durability on the shafts is an issue. Plus the stock/welded aluminum case is a liability again, at the mercy of the ability of the front driveshaft to slip and for minimal chassis flex.