Brainstorming

[RIPPEDK5]

I was just thinking about the idea of swapping transfercases in my '05 chevy

kinda like the idea of a manual shift and something stronger.. but again its just brainstorming.

my biggest concern is getting around the speed sensor in the transfercase.. If i wanted a 205 or even a 208 (idk why) then neither have a VSS in the case.. how would you get around that

 

[y5mgisi]

A guy here just a put a 205 behinde something like that. Cant remember his name right now but it will come to me! Ultimatley, he had to fabricate the speed sensors into the t case and add a grounding switch to tell the computer that the truck was in low range so it wouldnt freak out. supersize75 also is a wealth of info on the subject. They did still offer manual shift transfer cases in that year. I think robh just swapped his truck from button to lever shift but it was using whatever case he/they used in that year of truck that was lever shift. So it was a simple swap but not a 205. Thats all i got for ya for now.

 

[sweetk30]

fyi thay did offer the newer stuff with man shift option.

search ROB H member name . he did a soild axle swap on his 2500hd and ditched the electric one and swaped in man . he would be able to give info or read his thread.

 

[RIPPEDK5]

That was gunna be another thought, solid axle swap on a 1500.. doesnt seem to many people do or have the kits like a 2500 and up. and seems you need like 9" of lift just to put them under the truck, and thats illegal here. (lift law restrictions)

but i may look into the manual shift of that year... may seem like alot of nonsense, if it works already but these transfercase have some issues that include slack or play and clunking and electronic failure, also the failure of the internals and the cases cracking.

I didnt know if there was a simulator or adaptive setup you could put on a case to simulate the information to the computer, kinda like they have 02 simulators and check engine light eliminators for diesels

 

[sweetk30]

wasnt saying to sas swap it . just read his build thread were he swaped in the man version for the year.

and if you did a 205 you would need a ford case and swap in gm input . then can modify the tail to take the tone ring inplace of the speedo gear and also drill / tap for 241-up style speed sensor.

 

[jt512]

A little off subject, but, and feel free to correct me if I'm wrong.......but GM did make a VSS 205, granted it's the wrong side drop, pretty rare, but, they were made. A manual shift VSS driver side drop 241 should be easily attainable though.

 

[sweetk30]

1991 k30 with 205 was 1 year only. and rixed yoke rear would not matter on drop side for the parts only to swap to ford case per say . but big cast housing part would be diffrent.

 

[greatwhitez71]

Lemme help. In your case a 241 would be you're best bet. The 88-98 1/2 tons and 3/4 tons all have the ones you need and it should be a bolt and go process. This WILL cause a few lights on the dash and the computer will not know when it's in low unless you can figure out how to wire in a switch or some other way of telling the electric transmission that you have manually shifted to low.

Also, dig around. There's a thread somewhere that tells you how to retro fit the 241 vss and tone ring into a 205 case. A 205 case will not be quite as plug and play but it is possible.

 

[COCHEV]

Can i ask why anyone would want to put a 205 in a newer rig unless they were doing some kind of doubler? They are big, heavy and a pain to shift. Are people really breaking the newer cases or is it just cool to have a 205?

I do, however like/agree with a manual shift t case. Just my. 02

 

[Fordum]

Can i ask why anyone would want to put a 205 in a newer rig unless they were doing some kind of doubler? They are big, heavy and a pain to shift. Are people really breaking the newer cases or is it just cool to have a 205?

Well, in my particular situation, I swapped out a Borg Warner 1356 aluminum case which is a pretty good case, for a 205 so I could have a PTO winch on an automatic transmission.
They actually made a 1356 with a PTO opening, and that is what I ordered the truck with.
The stock case was all aluminum, and the PTO case was half magnesium for more strength.
But, apparently that was not enough, because they discontinued that option before my truck came in, so I had no PTO opening.
If I was going to replace the transfer case in that 3/4 ton, I wanted something I did not have to worry about, and the 205 was a cheap and easy swap.

I modified and made the shifter linkage to adapt to it, and it has worked for over 20 years, but one of these days I am going to order the adapter kit from that outfit that makes the twin stick option.
Probably stay with the single stick, but they make a nice linkage kit to adapt the 1356 shifter to the 205.

 

[RIPPEDK5]

there are alot of problems with the case,

mine makes noise and started at about 100k miles, swappped the mega expensive fluid (takes special fluid) to try and keep it happy but it still whines. My buddy already rebuild his transfercase (same auto-junk transfercase).. The pumps fail and the chain rubs through the case--very common, GM has a TSB out on it but its a very expensive fix. If the fluid swap doesnt work, and the t-case fails then its replacement anyways, and if i keep the truck itll happen again

I never get to use 4wd much (sadly) cause im also trying to figure out what direction i want to go with the truck still, but then you might ask, why swap it anyways.. well to answer that: its not about wanting a swap just because, If I do start wheeling it (If the truck goes up and not down), then the t-case will explode on me anyways and if im lucky leave me with an intact trans.