My 400 to 465 swap & doubler build thread *PICS*

[MTMike]

I've been accumulating the parts to swap a Hydro 465/203/205 in place of my TH400/205 for the last year or so. I got started on it earlier this month

Here's the tranny & t-cases. I will get them cleaned up before they go into the truck.

I got a new flywheel & clutch put on last week...

Then, I scored a factory pedal assembly & hydraulics from a junkyard for cheap on Saturday, and got it put in today.

I had to pull the steering column and all of the wires that were tied up behind the dash had too be pulled down to get the column out, so that's whey there's the big mess of wires. They're not pretty, but for a junkyard score I couldn't be happier.

The hole that is partially covered was there in the cab previously and it looks factory. Since the cab is a '74 the master cylinder needed it's own hole drilled and it almost worked in that hole, but not quite. So I had still had to drill a new hole to mount the master.

The next step is to get the twin stick conversion done on the 205 and look into a crossmember solution.

More to come in the coming weeks....

 

[MTMike]

Did some more work on the transfer cases

The output bearing is installed into the NP203 Adapter

The low range gear installed on the intermediate shaft

Installing the needle bearings into the intermediate shaft. Lots of grease holds them in place

Inside of the NP203 with the low range gear removed and ready for reinstall with the 203 adapter.

A thin bead of "Right Stuff" to seal it off....

And the 203 is all together.... time to clean it up and lay some paint on it!

 

[badmix]

Very nice, looks like your doing a good job with it.

 

[MTMike]

Thanks man! I appreciate it!

Did some more work this morning and got the NP205 adapter cleaned up and mounted.

The adapter and 205 mounting surface cleaned up

A thin bead of "right stuff" holds them together on the 205 side too....

All bolted up!

Test fitting without the center adapter

Test fitting without the center adapter

Test fitting without the center adapter

I think I'm going to use studs for the center adapter that mates the 2 pieces together. The instructions NWF has on their website says to use 3/8" x 7/8" bolts, but I don't like the idea of only 3 threads holding it all together, even if it is 4 bolts per side.

 

[MTMike]

It's been a while since I updated. With my deadline drawing near I've been blitzing to get it all done by Saturday the 12th, and havn't stopped to take pix along the way.

The tranny & t-cases are in, the cross-member is built and installed, the clutch is bed, oil is in the gearboxes, and the drivelines are in. She moves under her own power and a quick driveway shakedown and a lap around the block shows that she's running great.

So here's some pics. Yes, I pained the stuff purple for 2 reasons: 1) The wife likes it 2) It's different.... everyone's got red, orange, blue, etc, so I wanted it different

For the cross-member I used my stock rear unit, and then fabbed up one for the front using some 3/16" stock I had laying around. The welds aren't pretty but they penetrated well and are strong

Test-fitting the shifters & tunnel

 

[dremu]

That kind of purple ... well, it says you're quite comfortable with your manhood, that's for sure

Curious what you're gonna do with the panel for the triple stick and the tranny tunnel -- I remember mine taking up some serious time and effort, and I donno that it's worth it.

-- A

 

[MTMike]

That kind of purple ... well, it says you're quite comfortable with your manhood, that's for sure

.....what more can I say

Curious what you're gonna do with the panel for the triple stick and the tranny tunnel -- I remember mine taking up some serious time and effort, and I donno that it's worth it.

-- A

I finished it - but I havn't taken pix yet. I will try to do that tonight.

Since my cab is a 2wd I had to "persuade" the 4wd tunnel to fit. I got it to fit nicely, it looks "OK", but lets just say I had fun with a can of "Great Stuff" and a can of black paint to seal the tunnel to the floor and close the gap on the right hand side of the shifter boot assembly.

 

[dremu]

Since my cab is a 2wd I had to "persuade" the 4wd tunnel to fit. I got it to fit nicely, it looks "OK", but lets just say I had fun with a can of "Great Stuff" and a can of black paint to seal the tunnel to the floor and close the gap on the right hand side of the shifter boot assembly.

Ah yes, the expanding squeeze cheese. That stuff covers a multitude of sins.

My cover has weld, bondo, bedliner, and then paint ... to cover the sins of my total inability to weld sheetmetal =))

-- A

 

[MTMike]

Here's how mine turned out. It's not the prettiest thing but it's sealed up and functional

 

[muddermilitia]

Is that an older NWF doubler kit? Mine came with studs to thread into the 205 to attach the 205 adaptor. How much did you clock the 205?

 

[MTMike]

It is. I bought it off a friend who had it for a couple of years. It had grade-8 bolts in it, and I didn't like the fact that there were only 3 threads showing on 4 bolts holding all 130lbs of that 205 off the back of it, so I went with studs and steel lock-nuts instead.

I clocked it 2" (at least that's what I think... and hope... I did. ) Their guide to clocking was a little hard to follow

 

[muddermilitia]

It is. I bought it off a friend who had it for a couple of years. It had grade-8 bolts in it, and I didn't like the fact that there were only 3 threads showing on 4 bolts holding all 130lbs of that 205 off the back of it, so I went with studs and steel lock-nuts instead.

I clocked it 2" (at least that's what I think... and hope... I did. ) Their guide to clocking was a little hard to follow

Yea I agree on their clocking guide being confusing. I clocked mine 3"s up. I think I read that guide 50 times Where did you get those poly bushings from? I need to get a couple for mine

 

[MTMike]

Yea I agree on their clocking guide being confusing. I clocked mine 3"s up. I think I read that guide 50 times Where did you get those poly bushings from? I need to get a couple for mine

The poly bushings on the stock crossmember were on the truck when I bought it from the previous owner. I have no idea where he got them

 

[muddermilitia]

actually I was referring to those bushings on your new (purple) crossmember the round ones in this pic:

 

[MTMike]

actually I was referring to those bushings on your new (purple) crossmember the round ones in this pic:

Oh, OK. Those are just $2.99 Napa rubber bushings that I cut in half.

 

[muddermilitia]

Oh, OK. Those are just $2.99 Napa rubber bushings that I cut in half.

Ok, cool. Last question, I think , do you think it would be ok to use those in conjunction with Comp poly motor mounts?

 

[MTMike]

Ok, cool. Last question, I think , do you think it would be ok to use those in conjunction with Comp poly motor mounts?

I'm not sure on that. I've heard not to mix rubber & poly, but for what use this rig gets, I wasn't worried about it.

 

[royjones]

I have a ? Is there only 4 bolts holding the 205 on the adapter. does it need a support under it or Am i missing something

 

[MTMike]

I have a ? Is there only 4 bolts holding the 205 on the adapter. does it need a support under it or Am i missing something

I wondered that too, but from everything I read, it apparently doesn't.

 

[UPS]

What happened to the pics? Can you still see them?