CK5
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The Chicken Truck

Aluminum t cases aren’t the Achilles heel that the interwebs try to make them out to be.
That said, if what is in it works, it works
 
Aluminum t cases aren’t the Achilles heel that the interwebs try to make them out to be.
That said, if what is in it works, it works
I agree, other than this and a 205 I have in a 91 Dodge 1 ton all the transfer cases I've ever had were aluminum and I've broken a lot of stuff but never an aluminum case. The web wheelers have made the 205 the end all be all of the t case world.
 
Got the rear discs on...

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Drilled and tapped the hole for the third stud on the front passenger side spring plate....

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What are you guys thoughts on studs vs bolts? My two Dodges use studs and have been fine but the also don't see anything besides highway and dirt roads. I know from the factory GM used bolts but studs seem like they would hold better?
 
I am leaning heavily towards swapping the 208 in, it would allow me more flexibility with a front locker as well as the lower gearing. I should have everything I need. Ive been collecting parts, and so far have the shifter, t case, rear driveshaft. I believe the front shaft is the same and I think I can use the stock crossmember with a tall adapter? I wonder if I can get the 203 skid plate to work or does the 208 hang lower?
 
The front drive shaft got longer when the 208 came into service. I believe almost 3" longer.
Here's the 208 with the steel skid plate from a cucv. There was also an aluminum version. My 84 has the flat crossmember, I'm pretty sure in 85 they had the w shaped crossmember.IMG_20220421_164353871.jpgIMG_20220421_164338021.jpg
 
Well shit, thanks K10. For some reason I was thinking they were the same front, just a different rear, looks like I’ll need to pick one of those up! That skid plate doesn’t look much different than mine, I’m hoping I can make mine work.
 
K10, what trans are you running? I wonder if all the 208 front shafts are the same or if they are shorter/longer depending on 350/400/465
 
Copy that, all the same. I actually stole this drive shaft out of a 89 3/4 ton Suburban with the turbo 400 and a np241. My truck has a SM465.
 
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