Engine/Transmission (1994 - 1998) transfer case???????????

[b.ferrara]

thanks for all the responses, I know the southbend clutch was installed and the flywheel was taken care when put in. Rattle trap it doesn't have a sinle problem in 4low, I've driven it through all 5 up & down a dozen times, it's perfect. The second I put in to 4 or 2 high it starts doing it. I know never say 100% so I'm going to say 99% it ain't the clutch. I can not believe it's the transmission, like srath said Dan is one of the best, I set the transmission to him for that reason cross country. I'm working a 24 tomorrow, Tuesday morning I start to pull the t-case. Thanks for all the response, I'll keep the thread updated.

 

[RStankevitz]

wouldnt the chain in the tcase only slip in 4 wheel drive? i still lean towards the clutch and flywheel. how much difference is there in the slip if you are really gassing on it versus lightly taking off? if you have done everything else 2-3 times i would look into clutch and flywheel. it could be a defective unit from southbend?

I just dont see the tcase slipping in 2 wheel drive it is all gears and if it where messed up it should be completely dead

 

[cro-magnum]

Did the truck roll off the assembly line a standard or a auto. I would run a car fax or something to that effect that will tell you a little more about the truck. The bell housing could be causing some problems. Maybe putting the throw out bearing in a bind or the slave cylinder. I have never experienced anything like that but if its not the obvious its gonna be something you never expected. As far as the transfer case I agree with who ever said replace it with a 205. (gear driven and all). One out of a first gen should fit i guess. I put the NV4500 in my 1st gen, getting the transfer and trans together was a matter of seals and bolts.
see ya
Travis

 

[cro-magnum]

If you took out one gear in the t-case you'll eventualy take out the rest. and you would know if you did by draining the oil.

 

[rattle trap]

cro-magnum, nice thought, but no dice.



wrong side drop. you would need some type of older ford t case. divorced would be ok too.

 

[cro-magnum]

Oh I see rattle trap. Thats odd though cause there is no need for an adapter for the swap I did. Smart on the builders part I guess, they kept the patter the same for both side drops.

Travis

 

[rattle trap]

Oh I see rattle trap. Thats odd though cause there is no need for an adapter for the swap I did. Smart on the builders part I guess, they kept the patter the same for both side drops.



Travis

you shouldnt need an adapter. you used original t case in your 1st gen, correct? it drops over on the passenger side. in order to use a 205 in a 2nd gen you need a drivers side np205 which is found on 70s and maybe 80s fords. i cant tell you if the ford 205 is patterned with the 6 bolt clock pattern or the 8 bolt race track pattern.



i only mention divorce as an option since many ford cases are divorced and all factory cummins trucks have enough wheel base to be compatible with that case. then you need a 2wd output/yoke and a jack shaft between the 2.

 

[b.ferrara]

I know some guys are hung up on the clutch, but I've had this same problem befor I re-placed the clutch. Over the past 5 years the only temporary fix was the transmission and transfer case, I drained the fluid last night and found a few little pieces of metal and some gasket sealer. I'm going to pull the t-case tomorrow and have it opened up.

 

[SRath]

I have a Ford NP205 I am planning to install behind an NV5600 to replace my NV4500 and NP241. Ford 205's use a round bolt pattern. However, it is necessary to get an adapter kit consisting of a spacer plate and a 29 to 32 spline spud shaft from Advance Adapters.



I contacted AA awhile back because the kit is intended to put an NV4500 in a Ford truck with a stock NP205, so the spacer is only about an inch thick (to keep mounting distances the same I guess?) and you must grind or cut a little under a half inch off the NV4500/NV5600 (same outputs) output shaft.



I do not want to do that and asked AA if they could simply machine me a . 500 inch thicker spacer. No reply yet.



As I watched an auction for a COMPLETE Ford kingpin/lockout/leafspring Dana 60 assembly on ebay yesterday (It also had ALL the springs, hangers, shocks, brackets,, steering box etc. ), I was once again consumed with the urge to eliminate the thing I detest the most about my Dodge: That crappy front suspension and fake dana 60.



The assembly went very cheap, but it was just too far away for me to go get it.



I parked my Dodge and my K30 Chevy side-by-side and took a good look at the frames and suspensions and the real vs. fake dana 60 and coil vs. leaf suspensions...



It looks to me like I could possibly go with a Chevy or dodge NP205 (passenger side drop) and use the spare Chevy Dana 60 front axle i have... I think my front driveshaft might just barely clear the cummins diamondeye exhaust. . ?



I sure wish I had some junkyard frame to play with and find out...



Anyway, an NP205 can be done in our 2nd gens, but you also need to get one of those mechanical to pulse speedo adapters. They are fairly cheap. The AA kit is about $415.



A Ford NP205 is the same from any year or truck or transmission (Ford actually did something interchangeable and was much smarter than Chevy or Dodge there!). It also has the beefy input and output shafts.



I just personally do not like aluminum case chain drive t-cases. I have never broken an NP205.



I suppose I really should have just bought a 1st gen Dodge Cummins and simply replaced the Getrag with an NV5600 and called it "good"... or "great!"... Or found a way to put the cummins in my K30...

 

[b.ferrara]

I've had 2 suburbans, an 84 & 87, Ive also had a 1st gen dodge and a 87 k5 blazer that was built from the ground up. The 350 gasser and all of it components went in the garbage. 6. 2 with a 3spd manual and a 205 t-case want an awesome truck I sold it on ebay about 6 months ago. I just had 2 many vehicles, still do. If I could do it all over again, as much as I love the 2nd gen truck I would of bought a 1st gen ext cab.

 

[cro-magnum]

That is some great info SRath. Why do you say the dodge has a fake D60? I have a D60 out of a 92 ford for another project, but I haven't put the 2 60's next to each other for comparison. I forgot to mention I have a 1st gen not a 2nd is the 1st gen D60 fake too?

Hey Rattle trap I did keep my transfer case in the swap. I just assumed a first gen 205 would work based on the bolt pattern. I don't know anything about the 2nd gens so I should have kept my mouth shut about the swap. Having this conversation with you gave me another idea for Ferrara.

Maybe an atlas 2 would be an option for you. I'll do a search now for some more info. They are expensive but I would say your whole situation has been that way.

 

[SRath]

I call the 2nd Gen Dodge's front axle a fake Dana 60 because it lacks everything that ever made the Dana 60 the legendary front axle it was except for the center section (carrier). There is alot more to a front axle than that.



Gone are the much stronger and more durable kingpins, replaced as a cost-saving move by stinkin' balljoints which are fine for cars and 1/2 ton pickups, but not HD pickups.



Gone are serviceable tapered roller wheel bearings. Again, a penny pinching move by DC that ends up costing owners many times more money to replace the weaker and less durable unit hub and bearings.



Gone are the ultra-reliable and easily serviced lockout hubs with their true free-wheeling ability. Replaced by a complex vacuum operated CAD (central axle disconnect) that will let you down when need it worst and also turns one side of your front axle 100% of the time causing excess wear and sucking more fuel.



It gets worse: The axle housing is significantly weakened by the CAD assembly. Given the weight of the Cummins and the weight of my snowplow, that is a very bad thing.



Inside, again due to the misconceived CAD unit, you will find small, Dana 44 inner shafts! NOT 1. 5" dana 60 shafts! The passenger side wimpy shaft has a weak sliding collar to join the TWO pieces together. Yeah, a smaller diameter two-piece shaft to replace a beefier one-piece... How is that acceptable? An assembly is only as strong as it's weakest component. This abomination has nothing but weak components!



So go ahead, crank that torque monster Cummins up. Install big tires. Get into some rough offroad situation and watch that front axle disintegrate...



All in all, it is the most undesirable, weakest Dana 60 front axle ever conceived or built and is not even worthy of the name.



DC engineers stuck their heads even farther up their backsides to dream up the nightmare we all affectionately know so well as the "Dodge Death Wobble".



There will be all kinds of guys try to tell you how much better a coil spring suspension works, but in the case of a non-desert racer or non-rockcrawler that is total bull. Especially when it eats tires, parts, and thousands of dollars as quickly as these do.



K. I. S. S. > Keep It Simple Stupid. This fundamental engineering concept along with "Don't 'fix' what isn't broke" should be tatooted across the foreheads of the DC engineers responsible for this junk, right before they are fired and kicked out the door!



Front leaf springs forever!



cro-magnum: Your 1st gen Dana 60 is the real deal. Dodge has long used goofy unit bearings and hubs on some models, and I have always been a Chevy man, so I don't know what your Dodge 1st gen front has for wheel bearings and hubs for sure. I do know that you can easily interchange the beefy chevy dana 60 into a 1st gen. ifyou needed to or if it provided better hubs and bearings. The chevys have excellent 35-spline inner shafts.

 

[cro-magnum]

Ok I see what you mean. My girlfriend has the same set up on her 2000 1/2 to in the 44 model. Im in good shape then I don't have any of the weakness's you mentioned. I agree Dodge and Dana lost track for a bit but so did everyone else. They started catering to people that wanted a truck, but didn't want a TRUCK. I have to say I think that Chevy led that race (only an opinion). I do agree though I just sold my 05 3/4 ctd and went back to my old 91.

Good talking to ya
Travis

 

[SRath]

Yeah, Travis. Chevy lost this true-blue bowtie man when they went to that miserable torsion independent front suspension.



The thing is, kits are available to fit a Ford Dana 60 into them with ease now. But nothing so far for the dodge.



I think the guy that gets the swap of Ford leafspring, kingpin, high pinion D60 down pat for a dodge could make some bucks off it. The real problem is finding those Ford D60's. The Chevy guys scarf 'em up.



I like my dodge, but I like my K30 454-powered Chevy just as much. More when it comes to toughness. My only reason to buy the Dodge was the Cummins and NV4500. Of course, that was when diesel was still cheaper than gas...



The K30 is coming out of mothballs soon. My 14 year old son will be driving it to school when the weather is too nasty to drive the '73 Camaro. He may end up with the Dodge since he only drives 6 miles each way and I drive 16... i guess it depends upon gas vs. diesel prices and how the math all works out.



I've seen 1 or 2 really well-done Cummins into Chevy conversions and would still like to do that someday if diesel comes back down to earth.