Best combination for Highway Driving \transTcase

[obijuan]

Everyone sticker pecks out for 205s here. 241s get scrapped or sold super cheap. High mud truck volume here?

[roxxx]

Originally Posted by obijuan

Everyone sticker pecks out for 205s here. 21st get scrapped or sold super cheap. High mud truck volume here?

LOL that's funny I have two 205 sitting in my garage plus what I have on my two trucks I seem to trip over them . Wreckers charge such a premium for anything and with car parts Dot com they all know that everyone else is charging

[argonaut]

I went ahead and notched my adapter last weekend.
I was bottoming out on the seal retainer / seal retainer bolt heads. I have a few photos that I need to pull off the camera tonight and post.

Larry, what have you found?

I've also been looking for passenger drop np241s for a while now and haven't come across much. But then again I haven't been looking that hard.

[DirtyLarry]

Originally Posted by argonaut

Larry, what have you found?

nothing yet, haven't had a chance to play with it. We have a new baby that takes up a lot of time and I forgot about a few Christmas parties that ate up what would have been free time this past weekend. Hope to work on the cover tomorrow

[ryanroo]

I'd best chime in. as for the the best combo, i'm going to leave that up to your taste. a rebuilt 205 with proper idler shaft endplay is quiet as a mouse. a little scotch brite pad love on the shift rails and they shift like butter. so at that point it really depends on what you have easy access to in my opinion. i would be totally happy with either option. if you run the risk of tapping the case with a rock or something i would avoid the aluminum case. if you plan on sled pulling with huge diesel torque, then i would avoid the 205.

Now, for my experience in 4500/205. i have a round pattern case from an 88 V30 3+3. it came with a fixed rear. i upgraded the front output to 32 spl. i rebuilt the case. this one didn't need any bearings, so i did the full seal job and set shaft endplay to spec. i retained the long input and used an Advance Adapters spacer. this eliminated any issue with the shift rods and shaft nut. i have no complaints. it has been in my fullsize Jeep behind a 454 for four or five years. no issuses whatsoever. given the chance, i would do the exact same thing again. the benefit i see with the spacer is the longer front driveline. that can be an issue depending on the use of the truck. it might also make the difference between a 2 piece rear and 1 piece. that just depends. it also eliminates the need to modify the tail housing of the 4500. the one gripe i had about the spacer was the "studs" they send with it. they are just cut pieces of all thread. i used real studs for mine. i doubt it matters at all, but it would have bothered me when i was sleeping.

I also used the AA kit for adapting a 10 spl figure 8 205 to a 4500 in a different truck i had. the entire package was purchased from AA. they had done the necessary modification(new trans) and rebuilt the 205. i had nothing to do with that part, so DirtyLarry has a better understanding of that procedure. i also sold the truck before i had many miles on the combo so i cant review it in terms of longevity or problems. I much prefer the round pattern case process. it is much simpler and can be done without any need for permanent modifications to any OEM parts. that means it is easier to work on in the future.

And since Larry is posting pics of 205s, i better do so too!





this is the best shot i have of it all bolted together



here is the spacer. what of it you can see.



Hey, its Larry's case! i almost literally tripped over this one maybe 3 days after i bought the one in my jeep.

[argonaut]

Ryan,
I think that maybe that adapter-spacer is okay for a long bead, but in a lifted short bed pickup it makes the rear driveshaft length that much shorter and the angle that much worse. That's why I'm going down this route, and I suspect may be the same for DirtyLarry. If memory serves this NP4500 with 4wd tailhousing is about 3/4" longer than the SM465 with figure-8 tailhousing.


Some pics of what I have so far are here

[DirtyLarry]

Jason,

Looks like you and I used the same process for making the range rail hole.

I noticed on mine I needed to make clearance for the range rail pin so it wouldn’t hit the adapter when in the low range. That is why there is some meat ground away below the shift rail in the adapter


Precision machine work required. 1” wood spade


The input bearing seal retainer bolts definitely interfere with the adapter


After some rat tail file work and flat file work to the seal retainer face


Now I just need to get the trans and old tcase out of the truck and slap all this crap together

[obijuan]

now how are you guys gonna shift these things?

[DirtyLarry]

Originally Posted by obijuan

now how are you guys gonna shift these things?

With my hands

Hehe, actually, I’m running the ORD twin stick

[obijuan]

ah ok. ive got a doubler with the ord shifters. gave me a whole lot more room. i know exactly how yours works then.

[argonaut]

I'm tentatively planning on tapping a standoff on the right side of the NV4500 case, but I need to take some measurements to see where it will land in on the transmission cover floor piece. I don't want it to be too far forward or too far to the right.