Another NV4500 to NP205

[Orange Crate]

I was in the garage last night tinkering with my NV4500 and NP205. It took me probably 2 years to find a round 6 bolt pattern NP205 but one finally popped up on CL. I couldn't get my wallet out fast enough! Not bad for $200! It also took me about a year to find an early NV4500 and I found that on a business trip and threw it in the trunk of the rental car to get it home! I removed the long input shaft and installed my new short input. These pictures are with an empty case as I need to go through the bearings to see what their condition is.I have a couple of other NP205s so I may swap the guts from one to the other to get the best parts. I have a cast iron 4500 to 205 adapter and it needs to be modified slightly along with the bearing retainer to allow the 205 to mate up completely. If you don't make these mods the 205 will have a slight gap and it could possibly crack the adapter if you pull the two together with the hardware. I used a die grinder to remove material on the bearing retainer face and the inside of the cast iron adapter.

[Orange Crate]

Wow it has been a long time getting all this together (literally!). Here is the complete new input and rear output assembly. I started to mod the cast iron adapter to accept the upper shift rail. It is close to being done. You can see my twin sticks in the shot. I was lucky to find another stock shifter so I welded two bolts together to mount them. I also converted the front 30 spline output to a F(T)erd 32 spline. I probably didn't need to do this but my complete drive train will be 1 ton from front to back when I'm done and the 205 is all apart so why not. Well that's all the pictures I took last night so..back to the garage!

[snj8198]

$200 for a round pattern 205? You stoled it! I paid $300 just for the empty case.

[Orange Crate]

Originally Posted by snj8198

$200 for a round pattern 205? You stoled it! I paid $300 just for the empty case.

The guy knew what he had too, and let it go for that...! A true fellow truck builder but changed his direction mid stream. I could have bought a JB LoMax kit and put this together two years ago, but $$.

[snj8198]

Ya the low max is costly. I don't like how they market it as a 205 yet in order to get the 3:1 gear ration you have to buy their case. If im paying out that much im going all the way to Atlas.

What are you plans for the truck?

[Orange Crate]

[QUOTE What are you plans for the truck?[/QUOTE]

The way I'm building it, it should be able to handle just about anything. I plan on putting a low profile camper shell on it and go explore the back country. I probably shouldn't have spent the money I did on the paint but it will look good for a while. I see in your signature you are injected also. Sounds like we have similar trucks. What do you get up to in yours? I have another thread going in this section concerning a Hickey worm drive winch so I am in the process or rebuilding that right now also. Yes, I think I have tinkeritis pretty bad.....

[franken]

Nice. I have a similar setup in the garage w/ a round 205, 96 trans, iron adapter and planetary range box.

[Orange Crate]

Originally Posted by franken

Nice. I have a similar setup in the garage w/ a round 205, 96 trans, iron adapter and planetary range box.

Planetary range box, that sound serious. When do you use that? I have a 92 NV and 4.56 gears so Ill need to be at around 33" on tires with the O/D.

[SunSoaked]

This thread sounds eerily familiar! Picked my nv4500 up on a business trip and drove it home in the trunk of a rented mustang. Twin sticks? Yep. D60,14ff and 4:56? Yep. I'm installing my Edelbrock Pro Flo this weekend.

[Orange Crate]

Great minds think alike? Yours looks like it is done and I just ordered my bearings and gasket kit for my 205. I still need to go through my NV4500 so that will be at least a couple more months for that (just in time for spring install, maybe). I ordered all my bearings from the local bearing house and got all Timken. A little more $ but I'll feel better when it's done and buttoned up. It will be the last 205 I'll rebuild.

[franken]

Originally Posted by Orange Crate

Planetary range box, that sound serious. When do you use that? I have a 92 NV and 4.56 gears so Ill need to be at around 33" on tires with the O/D.

The planetary is from another TC, like a 241. The 205 has a 1.96:1 low which some consider not low enough. The PO swapped the original 205 for a 208 for that reason. It gives the TC another low (1.96*2.6).

A similar mod is using an NP203 range box to do the same thing.

[SunSoaked]

What did you use for a bellhousing? Mech or juice clutch?

[Orange Crate]

Originally Posted by SunSoaked

What did you use for a bellhousing? Mech or juice clutch?

I missed this question. I haven't made a decision yet on the bell housing. I'd like to go with the AA BH but $$. I read the post below. He drilled his NV4500 to fit a standard 4 speed BH. You have to bolt the two together from inside the BH and install it that way but that's the way auto trans are anyway. Decisions...decisions....

http://67-72chevytrucks.com/vboard/s...d.php?t=611566

[b454rat]

Plan on doing this to a Ford 205. Swap input to short shaft, then drill n tap the face of the 205. Good read!!!!

[snj8198]

What do you get up to in yours?

Mileage wise? With my current Straub cam i get 11mpg. I got 12-13 with my prior Comp Cam but there were different characteristics to both.

The planetary is from another TC,

You going ORD?

[Orange Crate]

[QUOTE=snj8198;8087068]Mileage wise? With my current Straub cam i get 11mpg. I got 12-13 with my prior Comp Cam but there were different characteristics to both.

Ok, so it wasn't built for mileage, mine either. I was asking about what do you use your truck for?

[snj8198]

[quote=Orange Crate;8087159]

Originally Posted by snj8198

Mileage wise? With my current Straub cam i get 11mpg. I got 12-13 with my prior Comp Cam but there were different characteristics to both.

Ok, so it wasn't built for mileage, mine either. I was asking about what do you use your truck for?

Towing, hauling, and general daily duty. The heaviest i've rolled across the scales is 19,890 lbs with a 31' toy hauler.

[Orange Crate]

[quote=snj8198;8087803]

Originally Posted by Orange Crate

Towing, hauling, and general daily duty. The heaviest i've rolled across the scales is 19,890 lbs with a 31' toy hauler.

Now that is impressive. I am hoping that my truck will be able to handle similar situations if I need it to. I have an "RV" roller cam that is "all in" before 5000 rpm couple that with the 406 with TPI it "should" be able to pull a house, we will see....Painted the 205 case and the cast iron adapter last night so now I just need my bearings and gasket kit. I'm looking at NV4500 rebuild kits now....

[snj8198]

[quote=Orange Crate;8087828]

Originally Posted by snj8198

Now that is impressive. I am hoping that my truck will be able to handle similar situations if I need it to. I have an "RV" roller cam that is "all in" before 5000 rpm couple that with the 406 with TPI it "should" be able to pull a house, we will see....Painted the 205 case and the cast iron adapter last night so now I just need my bearings and gasket kit. I'm looking at NV4500 rebuild kits now....

neat! i like the 400 small blocks and roller is the only way to go now days. While building for go dont forget the whoa. Hydro boost transplanting is not that hard. Consider looking into it. 600+ ft-lbs is nice for getting the house moving but 4 wheel disks and hydro boost is nice for slowing it down again. Consider sway bars for keeping things under control through the transit too.

[franken]

Apologies to the OP, since I've hijacked. Please don't ask about my conversion in new posts.
Mine is from box-rocks or something like that on pirate. Good guy.

[Orange Crate]

Some progress. Got all my Timken bearings and the gasket kit installed. I have a 1350 yoke for the rear output but I still have the old stock CV and drive shaft for the front. I upgraded the front output to a 32 spline so I'll have to make a decision on what I want to do for a front drive shaft. Any suggestions? I was thinking of going with a flat flange output and then a flat 1350 bolt on yoke. The truck has a 2" lift with a D60. I would like to have all 1350 u-joints in the drive train. Damn this thing is heavy, had to use the overhead hoist to get it bolted to the NV4500.... I have a case of high temp silver paint so.....

[SunSoaked]

I used a flat flange and CV on my 85 with Dana 60. Works great.

[Orange Crate]

Great, what size joints? What is your lift? Who made your DS?

[SunSoaked]

I swapped in factory k30 (cucv) axles in to my K20. It was a direct bolt in. I believe the front joint is a 1330. Rancho 2 inch lift. I haven't swapped the trans yet but, my measurements tell me I'll need to shorten the front shaft a few inches due to the shorter overall length of the trans/t-case length.

[snj8198]

How's this project going OC?