Engine/Transmission (1998.5 - 2002) Np 205

[FGunckel]

I have a NP 205 transfer case from a previous gas powered truck and was wondering if is worth transplanting to my second generation dodge cummins while I am replacing my NV 4500 manual 5 speed with a G56?



Specifically:



1) Will a 205 transfer case hold up to the torque of a 1998 1/2, 24 valve cummins (lightly modified but carrying a heavy camper and used in moderate off road situations) or would I be better off retaining my current chain drive transfer case?



2) If a 205 transfer case is inadvisable, would a more current transfer case give me so much greater reliability and strength that it would be worth the expense of installing it while I am replacing my NV4500?



Thank you in advance for your suggestions.



Fred Gunckel

 

[ata]

The NP 205 was used in the 89 to 93 Dodge Diesel trucks. The NP 205 is the best OE T-Case out there. It's gear drive NO crap chain that fails.

 

[FGunckel]

Thanks, ATA for your comments. I'm hoping others on this forum will chime in with their opinions.



F Gunckel

 

[AndrewKing]

HI,

I'll second the NP 205 comments..... it is definitely BEEFY!

Andrew

 

[chevota84]

I've never broken a 205 and not for lack of trying. I have one in a 72 blazer that I've owned for 21 years with countless motors up to a stout 454 and I wheel the hell out of it with no problems. I also know of a couple of 1'st gens with 300+ rwhp that have never had a problem either.

 

[FGunckel]

Thanks Andrew King and Chevota84. I'll plan on using my NP 205 when I rebuild my drive train based on your comments.



Fred Gunckel

 

[BDaugherty]

I've only broken one NP205. The NP205 is legendary, for sure. However its strenght is the strong housing and the gears that it uses to transfer power to the front axle. Some versions are stronger than others. For example, the 10 spline male input is very common, but not nearly as strong as the 32 spline female. The NP241HD transfer cases used behind NV4500s in Cummins applications are plenty strong. The power is transferred straight through the case via a pretty beefy shaft. However, the weakness come in if you use the 4wd either a lot or in extreme conditions. The aluminum housing doesn't like to hit stumps or rocks. Also, while the chain itself is plenty strong, the planetary and bearings used to transfer power to the front axle are not up to the task of big tires. It depends on what you're gonna use it for. Driving, towing, and occasional use of 4wd won't hurt a NP241. If you're gonna do a lot of off roading, it might be worth your extra effort to adapt the 205... if it's one of the stronger versions.



Just my $0. 02.

 

[FGunckel]

Thanks BD for your comments.

 

[MarkMiller]

If your looking for the beef check out what he sled pullers use. Can't get much more abusive that what they put their rigs through.

A 205 is pretty stout though. As is the 241HD. The gearing advantage goes to the 241 though, a 2. 71 low range versus a 1. 95 in the 205. So if the low range advantage is what your after stick with the 241. You can also go with an aftermarket box like the Stak http//www.stak4x4.com/ 3 speed if you really want to get nutty.

A 205 does not like high speed running. The oiling system in it just doesn't deal well with the heat generated. A 241 will take higher speeds better and for longer distances.

I don't really have an opinion on which is better. I have a 205 in my Jeep with 42 inch rubber and I have a 241HD in my 99 CTD that is on 37 in tires with 500 RWHP. No complaints about either.

 

[MAX A/C]

I prefer the lower gearing of the 241. Made a noticeable difference when I went from my 1993 to the second gens. I was concerned with the perceived lack of strength from the 241, but seeing how the sled pullers/drag racers abuse them with minimal failures gives me peace of mind. I know the cost of such a swap would not be worth it to me, but YMMV.

Scott

 

[JohnsonJim]

I thought that starting in 1994 that the front axle on the Dodges went to a drivers side drop... so if you want to use a np205, you need to source one from a Ford, as the GM and Dodge versions are passenger side drop.



G56 is 29 spline and the dodge 205's diesels are 29 spine too. Chev 205's can be 32 or 10 spline and the fords are 31.

 

[Floyd4runner]

i agree

Can't helpbut agree withe everyone. I have a 203/205 doubled TC setup in my crawler and would not take for it. But in my 99 dodge at highway speeds I like the 241 and the low range it offers. Also the ford cases with a driver drop would all have the big bearing case instead of the small input bearing that is used on the male 29 spl dodge cases. All cases will interchange parts so you could put the dodge input shaft into a ford case but you would have to find a bearing that would fit the big hole in the case and the small shaft. Also I do not know if the adapter will bolt up to the same holes in the ford case. Ultamately I would stick with the 241 if you wanted a lower gear if your sled pulling or mudbogging the 2. 0:1 is the better ratio.