Talk me into a NP205, or not...

[dyeager535]

I haven't ever gotten super deep in the 205's. There is a 10 spline input 205 for the manual trans, but that's all it was used on. AFAIK there is a 27 spline (when mated to TH350) and then the 32 spline units used factory with TH400's, '85+ 465's, and the 4L80E.

One of the "good" things IMO about the '85+ setups is that if using stock adapters, the adapter "feet" are much shorter on the later stuff. They seem to be a weak link (relatively) on the 465/205 combo, but not sure if the same issue happens with the thinner automatic adapters.

I totally understand using what you have. When you start changing things, it just multiplies the number of other things that have to be done to accommodate that change. It increases cost, and time necessary to complete.

 

[Green Monster]

I faced the same choice.....rebuild 203 or swap to 205. Went with the 205. Decision boiled down to two things. One, the 205 is indestructible. Two, it's gear driven, part time. Easy choice for me, but it was an expensive swap as the 205 had to be rebuilt and I needed new drive lines. Also switched to a CV in the rear as I couldn't eliminate the vibration. All is good now!

 

[MountainmanID]

I faced the same choice.....rebuild 203 or swap to 205. Went with the 205. Decision boiled down to two things. One, the 205 is indestructible. Two, it's gear driven, part time. Easy choice for me, but it was an expensive swap as the 205 had to be rebuilt and I needed new drive lines. Also switched to a CV in the rear as I couldn't eliminate the vibration. All is good now!

What did the 205 rebuild run you and who did the work?

 

[Bent77]

What did the 205 rebuild run you and who did the work?

There’s not a lot going on in there. Unless the gears are toast or the case split, some bearings and gaskets should cure most all ailments

Because of that, it’s completely doable at home

 

[onetonbb74]

My 205 was rebuilt by ORD and shipped to my door, it was a grand plus shipping...this was 2005 pricing. It did not come with either yoke, but they were 32 spline shafts front and rear.

 

[onetonbb74]

Ive rebuilt it since then and was super easy, couple hours on the bench, couple hundred in parts.

 

[sweetk30]

np205 is stupid easy to rebuild . here is a step by step with lots of pics . skip he first section on np203 range box . https://ck5.com/forums/threads/4l80...05-ord-doubler-3-sticked-its-all-done.253000/

 

[Green Monster]

What did the 205 rebuild run you and who did the work?

C&C transmissions in Thousand Oaks and it was just north of $900. But everything is crazy expensive here. It's probably a $600 job anywhere else. But he did have to replace some parts. Wasn't just a cleanup and seal job. Also, I just saw some folks chime in that it's an "easy job".......well, not for me. I had the step by step instructions and couldn't pull it off. Way over my head.

 

[MountainmanID]

np205 is stupid easy to rebuild . here is a step by step with lots of pics . skip he first section on np203 range box . https://ck5.com/forums/threads/4l80...05-ord-doubler-3-sticked-its-all-done.253000/

Well I might do the doubler build since I already have a 203 and its just the chain portion that is sloppy. Plus, having 3 sticks is tits awesome.

I'm sticking with 4.10s on the 37" rubber I picked up today and if I can keep my TH350 transmission, having that 4:1 ratio with the doubler would really give me some crawl ratio since I should probably be running 4.56s. The 4.10s are just to help out with running down the highway which is about 80-90% of this trucks future, 15% on logging roads, and 5% in mud or on the rocks.

There's a big part of me that wants to go to a 454 with a 700R4. If I can find a good deal, I'll probably do it. This is the original engine in this truck with 87k miles, with good compression on all cylinders. I've got some oil leaks that gotta be taken care of that seem to be coming from the valve covers but I have a suspicion that there might be some leakage from the intake manifold as it's a Edelbrock mani and carb and I bet the guy who did the swap probably reused the gaskets.

 

[sweetk30]

C&C transmissions in Thousand Oaks and it was just north of $900. But everything is crazy expensive here. It's probably a $600 job anywhere else. But he did have to replace some parts. Wasn't just a cleanup and seal job. Also, I just saw some folks chime in that it's an "easy job".......well, not for me. I had the step by step instructions and couldn't pull it off. Way over my head.

i did this write up with pics on my first ever 203 box and 205 rebuild with lots of parts swapped around .

 

[obijuank5]

It doesnt sound like you need a doubler st all. Watch out for the MAW.

 

[Bent77]

Well I might do the doubler build since I already have a 203 and its just the chain portion that is sloppy. Plus, having 3 sticks is tits awesome.

I'm sticking with 4.10s on the 37" rubber I picked up today and if I can keep my TH350 transmission, having that 4:1 ratio with the doubler would really give me some crawl ratio since I should probably be running 4.56s. The 4.10s are just to help out with running down the highway which is about 80-90% of this trucks future, 15% on logging roads, and 5% in mud or on the rocks.

There's a big part of me that wants to go to a 454 with a 700R4. If I can find a good deal, I'll probably do it. This is the original engine in this truck with 87k miles, with good compression on all cylinders. I've got some oil leaks that gotta be taken care of that seem to be coming from the valve covers but I have a suspicion that there might be some leakage from the intake manifold as it's a Edelbrock mani and carb and I bet the guy who did the swap probably reused the gaskets.

How much vacuum does it have?

 

[MountainmanID]

Enough to drive the brake booster

 

[tenderfoot]

It doesnt sound like you need a doubler st all. Watch out for the MAW.

That's just nonsense. Your a bad influence

 

[MountainmanID]

Middle aged wife?

 

[RootBreaker]

in 1989 My truck was originally a 1979 chevy k20 with 350/t400/np203/d44/14bff/3:73. Wheeled the crap out of it. no lockers, 33s with body lift... I knew my limits, got stuck often but had fun and the drivetrain never broke. had a b&m stage ii shift kit in it and it would rip your head off manually shifting on the column

1992
One day I'm driving down the road and this truck is on the side of the road with a FS sign on it. Hideous green ....
I crawl under it and on the d44 tag it says 4.56 ... woot...
so I buy it for $500...
1978 chevy k20 camper special 8400gvrw

swapped my body parts over cuz that other one was rusted apart. Guy said his son got mad at him and drove it into the atlantic ocean.. LOL

350/sm465/np205/d44/14bff/4:56
WOW the power with 33s.. was amazing. wheeled it hard and lots of clutch drops and drivetrain never broke.


since then d60 up front, detroits, 40" hawgs (38.8) on 12" steel rims... and a torquey 1991 sbc and still nothing has broken other than me shattering a rear ring gear (my fault)....

so hard for me to give you a good reason to go NP205... it is gear driven so I would prefer it myself over chain and saw a video on youtube.. guy did a rebuild on his desk and looked stupid easy...

 

[Green Monster]

i did this write up with pics on my first ever 203 box and 205 rebuild with lots of parts swapped around .

Yeah but you're probably a badass mechanic/fabricator! I know just enough to get me in trouble. I've paid the "idiot tax" many times.

 

[RootBreaker]

Yeah but you're probably a badass mechanic/fabricator! I know just enough to get me in trouble. I've paid the "idiot tax" many times.

Just renewed my membership

 

[sweetk30]

Yeah but you're probably a badass mechanic/fabricator! I know just enough to get me in trouble. I've paid the "idiot tax" many times.

never tore in to a t-case before i did this build up . and shade tree mechanic learned my whole life .

these 205 cases are real easy .

 

[Blue85]

The lift and tires were installed long ago and this is apparent whenever you shift from park to drive (CLUNK!!). The NP203's chain is obviously in need of replacement, along with a parttime kit.

What does the age of the lift have to do with a driveline clunk? Usually the clunk is in the differential spider gears. Old 10-bolts can have a lot of pinion rotation before the all the slack is out. The chain in the transfer case is only for the front drive. If you have unlocking front hubs and/or the part-time kit is disengaged, a loose chain won't have much affect on anything.