NV5600-NP205...Need Help!

[Marty1]

Does anyone here have a vast knowledge of these two units?

I'm mating the NP205 from my 93 Cummins to the NV5600. The transfer case physicaly bolts up fine. The coupling ordinarilly used between the NP205 & the Getrag is the right spline for the 6 speed but it's too long.

I thought I could just shorten it & infact did. It fits in fine & would work well... I thought. Upon further examination the coupling is totally different on the newer transfer cases. The NV5600 has a seal in the back & there's actually no coupling used on later transfer cases. The input shaft for the new transfer cases has this coupling built into it & it's smaller diameter... small enough to slide under the seal... you follow? I can't switch transfer cases because the front end is on the driver side on the newer trucks.

Any ideas?

 

[power grizz]

take the seal out. you have to do that on the nv4500 when you replace the getrag in the first gens. then the open area in the extension housing will carry transmission oil. the 205 will still have its front seal so there wont be any cross flowing of the two oils. that area is normally dry and dirty(it is sealed). then you will have to get a new coupler and put it together.



this i did on a getrag nv4500 swap and the six speed should be the same. you will have to get a linkage holder for the 4x4 as the 5 and 6 speeds dont have a mounting boss on that side.



hope this helps.

 

[Joseph Donnelly]

Can you machine down the OD of the coupler to fit the seal? As was said above, the junction is "dirty" so if you have oil in it, you will have to clean the area if there is any opportunity for that oil to go back into the trans (there will be if there is no seal), use RTV at the joint.

 

[Marty1]

That's exactly what I did, I turned the new coupling down to work with the 6 speed output seal. I used silicone in the spline to hopefully stop oil from leaking past the spline. I'll check the transmission fluid level carefully for the first while to see if it works.

I guess I should have just pulled the seal & filled the void with gear lube but I just hate doing that... just doesn't seem right even though I'm sure it works fine.

Got the NV5600 & transfer case in tonight... . Tight fit! I fabricated the transfer case bracket over the weekend & it works great. I'll try to attach a picture of it.

Thanks for the advice. #ad

 

[JRodgers]

Hey Marty, looks good. What are your plans for the front driveshaft? The 205 looks like the front output is on the passenger side. Are you swapping the front axle to one where the diff is offset to the right side instead of the left side of the truck?



Joe

 

[Marty1]

Joe,

My truck is a First Gen so my diff is on the right side!

I have a new transfer case from a 2001 with super low mileage that I'd love to trade for another NP205... anybody got one they want to trade?

 

[Philip]

Be sure to post and tell any glitches in the swap. What to watch out for and so on. There are a few 1st gen people interested in doing this swap.

 

[Marty1]

Surprisingly there were no glitches. The bracket for the transfer case was the trickiest part getting it perfect so the hole in the floor stayed the same.

If you use a 1999 NV5600 you don't even have to change the clutch or flywheel... in 2000 they went to the 1 3/8" input shaft & if you go that route then you can run the newer 13" clutch & flywheel. The hole for the shifter moves back 6 inches roughly & it would be much easier if you had a 99-2001 cummins wreck at your disposal because you need quite a few parts that Mopar charges handsomely for:

Transmission, Clutch housing, Adapter plate, starter, Clutch slave cylinder & master, clutch lever & spring, gear shift lever & knob, etc, etc.

The only fabricating is the t case shift bracket & transmission crossmember. I believe I can re-use my original crossmember & mount but slightly modified. Rear driveshaft shortened & front lengthened & your ready to drive.

Should be back on the road this weekend, if anyone wants a list of part numbers you can email me... I have them written down.

 

[bgilbert]

Marty1, very awesome post. If you don't mind maybe you can update us once you get rolling for awhile and post in the 1st gen forum. Plus more pics !!! Maybe some pics of the underneath, trans mounts, cross member etc. As Philip said, there's plenty of us 1st genners that are very interested in this swap. Maybe a new post in the 1st gen forum once this is completed describing the swap, needed parts etc. Heck how bout a article in the next TDR issue, thats it!! Thanks, keep up the good work. Bill

 

[Marty1]

Thanks Bill, I'd be happy to describe the process to anyone. That's how I got my information was by talking to Gil Hugley, a member of this forum who'd done this same conversion last year & many thanks to the guys at PDR... . they really are a wealth of information & have access to any part you'd ever need. I'm going to buy all my Christmas presents there next year! This year I bought my wife a nice new HX35 Turbo... boy was she thrilled! :-{}

 

[24VChev]

Great Post. I just posted a question about this conversion in another page on the TDR. I am doing the same thing but with a Ford NP205 (my diff is on the drivers side). I have a question about the coupler between the case and the trans. Is there a short coupler that joins the output of the trans to the input of the case. This is the coupler that you had machine down?





Thanks



Malcolm

 

[Marty1]

Malcom,

I'm not familiar with the Ford NP205 but if it's got the same size input spline as the output of the NV5600 I'm sure it's just a stock 89-93 Dodge coupling that you need. Then you can either remove the rear seal in the NV5600 & that coupling will work or else you can leave the seal & machine 3/4" of the coupling down to 1. 940" to work with the seal. That's what I did & then sealed the spline with silicone... seams to work great!

 

[24VChev]

T-case

The Ford T-case bolts up to the NVG 5600. I did not get any couplers with ether. I will go to my local bone yard and see what I can find. I will check with OEM also, you never know.





Just another question or two. Is the coupling a seperate part slips into the NP205 and over the output of the NVG? Or is the coupling part of the input on the T-case.



The shifter you made for your t-case, very nice job. Other than your bracket is the black lever a Dodge item?





Thanks for everything





Malcolm

 

[Marty1]

Malcom,

That's a stock Dodge 89-93 t-case shifter. The only mod I made to the shifter is you'll notice there is a 1" diameter land thats part of the NV5600 casting. I drilled the bottom bolt hole of the shifter to 1". Hard to describe but if you look at the picture you'll understand. That shifter used to have 3 mounting bolts... now it has 2 & the lowest one gets drilled... see what I mean?

 

[dcamilleri]

Malcom,

I just got done changing my 205 to the dodge input gear and coupler 1. 5 inch 29 spline after I stripped the splines off of my chevy nvg 4500 output shaft twice(1 3/8 32 spline) The dodge input gear for the 205 is a male shaft and the coupler is female 29 splines on both ends. I had to get a 2 inch thick spacer machined to come up with the propper length so I could have max. spline engagement. I am using a gm 205 case with the round bolt pattern and the gm tailhousing on my nvg 4500(longer than the dodge so that my spacer did not require being so long. If I can be of further assistance let me know. Dave

 

["Mad Max"]

Hodwy fellas -



I'd like to revisit this post if I may.



I was planning to use a nice '98 48re auto to upgrade my 93 CTD/auto, but I'm starting to really like the new 6 speeds.



In the process of acquiring parts I have the following: 48re adaptor, 48re, and a '92 np205 from an automatic.



Here's my questions:

1) Will the 205 I already have bolt up to the back of the nv5600?



2) Will the 5600 bellhousing bolt up to a '93 6BT?



Thanks all!

- Max

 

[Philip]

The auto 205 case has a different spline count and smaller output shaft size than the 205 manual case does.

 

[BManier]

Hey guys your talking about this wonderful coupler. What is the name or part number of this thing, where can I get one? And will this work if I machine it down on an np205 that had an auto infront of it out of a 78 ford with an 03 and up NV5600?

 

[DVolk]

NV5600-NP205... Need Help

Has any one or does any one know were to get a mount for twin

sticks for a NV4500/205 or a non gated shifting lever for the 205 ,

im haveing shifting problems with my 205 t-case ,but i think its the rails

going south it wont grab 4 low but high works or its the other wat around ,got to sit in truck to renember

either way ,i still hate that gated shifter

they make GMstuff bont wont fit the dodge stuff/or nv4500

 

[24VChev]

You can use the coupler from any 89-93 dodge with a np 205 that had a 5 speed in front. It will bolt togethe with OEM parts.



I have a 1 1/4 NVG6 speed with a 205 coupled to it sitting in my shop. if anyone is interested.



Malcoml