Divorced 205 Install

[Chevy1TonFun]

I thought I post my install for a good reference for those who are thinking or doing a divorced t-case install. For starters, I have done about 2 years of research before starting this install. I have also drawn up three different designs. I feel the design I am building is the simplest and strong enough to do the job.

One of the reasons it has taking me so long to start this project is money and tools. Well, after lots of selling parts and saving on my part, I finally bought the two most important tools for any 4 wheeler to have. A welder and tube bender.





These are the ideas that I have had in the past. I thought I would post them up for those needing ideas.












Next is the issue for shifting your divorced t-case. Here is one idea and my idea is a lot cheaper. Don't have a pic yet, but as well post it up after i build it.




Now for the build. Here is what I am starting with a NP205 Divorced T-Case out of a Dodge Truck.



I need to get some practice on the bender before I bend my $150 9'x.240 wall x 1.75 OD tubing. In the mean time I hope to get started on my shifting assembly. Until the next update, enjoy.

[67_SS396]

My suggestion, clock the case as high as you can. The designs you showed do look nice. Mine is not divorced and I also built a doubler, but wanted to provide some more mounting options. Good luck! I'm sure it'll turn out great however you decide to mount it.




Posted via Mobile Device

[Chevy1TonFun]

Thanks for the input and nice setup. I will be clocking my t-case a good amount. When doing a mock up, my rear driveline is going to be at 25*, front 18* an middle 11*. I'm hoping to get the crossmember built by next weekend. I'm a planning on doing some bending today and tomorrow.

[67_SS396]

I also forgot to say I'm a little jealous of the air/hydraulic bender. That will make things real nice and much easier. The JD2 bender I use is all manual, but hoping one day it gets upgraded to air over hydraulic.
Posted via Mobile Device

[Chevy1TonFun]

Originally Posted by 67_SS396

I also forgot to say I'm a little jealous of the air/hydraulic bender. That will make things real nice and much easier. The JD2 bender I use is all manual, but hoping one day it gets upgraded to air over hydraulic.
Posted via Mobile Device

Harbor Freight is your friend. Well sometimes. I am using a HF ram. It ram me $75. Can't beat that!

[Chevy1TonFun]

Picked up a Thermal Dynamics Cutmaster 42 plasma cutter this morning. I was waiting to pick up the plasma in order to build the shifting assembly. Got the shifter installed today. I think I may shorten the shifter. I am waiting for my new trans jack to come in before I start bending the crossmember for the t case. Here are the pics of the shifter mount:

[67mater]

I'm planning the same thing. How far back are you mounting the tcase? simple idea on the shifter; i hadnt yet figured out how I was going to handle shifting mine. keep us updated!

[Tex_50613]

those mounts are awesome, I hope you don't mind if I use some of your design aspects when I make the mount to install a divorced t-case in my '85 CCDRW that is getting a 7.3l diesel and hopefully a ZF 5 speed and divorced t-case

[Chevy1TonFun]

Please use any ideas or designs as needed. That is what this forum is for.


As for how far back I'm mounting the t-case, I don't remember the distance the last time I had it mocked up. I would guess some where around 8" behind the trans.

[69C20CUSTOM]

Wow you did a great job looks great.

I got a ?

What is the pros and cons of do a Divorced 205 I really want to but a 205 in my Suburban. Im going to do a big lift and swap to a manual trans so the divorced transfer case would help alot with drive shafts angles.

Thanks Ben

[Chevy1TonFun]

Well, its hard to say since I still trying to install mine. But here are a few pros:
1. its self contained, so no flow over from the trans issues
2. you can clock it how ever you build your cross member
3. BETTER DRIVE LINE ANGLES!!!
Cons:
1. Mounting has to be fabricated; no aftermarket parts to make install easy
2. An extra driveline - $$

Thats all I know for now. Anyone else have some more pros and cons?

[69C20CUSTOM]

Ya driveline cost is big in the back of my head cause im having to get new drive shafts with my big lift and auto to manual trans so I need to figure out what I want to do.

[8door]

By what I can see, your transmission is a th400 ?
NP205 seem to be a popular unit for Dodges, what is
the more common Chevy case ?
You put a lot of thought into and it shows

[Redcap]

Originally Posted by 8door

By what I can see, your transmission is a th400 ?
NP205 seem to be a popular unit for Dodges, what is
the more common Chevy case ?
You put a lot of thought into and it shows

NP205 is a common transfer case and, arguably, one of the strongest.

[Chevy1TonFun]

Yes, I have a Turbo 400.
The 205 case is the most common. You will find the 208 to be the next common, which is chain driven unlike the "bullet proof" gear driven 205.

I have put in about two years of research into this build while saving for all the tools I've needed for this build. I hope you all enjoy and can take any needed info to help with your divorced build.

[Chevy1TonFun]

I received the last of the parts last week. I hope to find some time this Saturday to start building the crossmember.
Posted via Mobile Device

[Tex_50613]

i'll be watching for sure being as i am only short a flywheel and clutch assenbly for my 7.3l/zf/np205 swap in my k30

[Chevy1TonFun]

Originally Posted by Tex_50613

i'll be watching for sure being as i am only short a flywheel and clutch assenbly for my 7.3l/zf/np205 swap in my k30

Is your 205 married or divorced?
Posted via Mobile Device

[Tex_50613]

devorced passenger side drop

[Chevy1TonFun]

Made a lot of progress today. Everything is cut out and finished the mock up. I drilled holes and mounted the t-case crossmember mounts. Hope to finish by next weekend.

[63chevyll]

So, by doing this will you be able to use the same drive shaft front and back?
I've heard of people doing this so they only needed one spare, since they will be all custom.
Posted via Mobile Device

[Chevy1TonFun]

No, the front will be a different length than the rear.
Posted via Mobile Device

[67mater]

first off your Cali floor makes me sick. Second, sweet design. Will you be able to drop the case out from the "craddle" or will the craddle be able to be tipped as it comes down? I was thinking of running a boxing plate through that area, and then you mounts would be inside the frame and the whole thing could slide out. Also, where did you get the bushings and mounts?

Nice job!

[Chevy1TonFun]

Here the link to the inner frame mounts:
http://www.polyperformance.com/shop/...Kit-p-433.html

The t case will unbolt from the "cradle" and out it goes. Then the cradle lifts up and pivots out.

Posted via Mobile Device
Posted via Mobile Device

[DirtyLarry]

That is some nice work! Out of curiosity, what will the divorced tcase gain you? Have you ever driven an old Ford or Dodge with a divorced tcase? Lots of drivetrain slop and clanks, even with new U-joints. Makes life easy if you ever go to an Allison transmission though. Your work looks great!