93 Bronco T-case

the 205 is supposed to be one of the toughest transfer cases around. all the electrical b.s. thats in it now is nothing but trouble, and the 205 is gear-driven. im thinking it would be a good solid swap, less trouble down the trail
 
find you a manual 1356 and swap it. the 205 is heavy as hell and even if you add the torque arm support it still can crack your tranny.
 
Atlas :D The 205 is stronger but is heavy as hell, couple that with gearing that sucks and the weight there are better options out there. On the other hand if you wanted a 205 I'd do a 241/205 doubler. It's lighter and better gearing than the 203/205.


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Franklin said:
find you a manual 1356 and swap it. the 205 is heavy as hell and even if you add the torque arm support it still can crack your tranny.
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It's not the weight, it's the difference in support between the torque arm and the motor mounts that cracks the transmission housing. There's maybe 40-50# difference in gross weight, but that's nothing compared to the driveline torque involved.

The other problem is that the 205 isn't necessarily a direct swap. The bolt pattern and spline count is the same, but you need to check the tail housing on your transmission and see if there's a cutout for the rear (inboard) shift rail on the transfer case. It basically ends up between two of the bolts on the transmission tail housing. (Cutting a notch in a transmission that didn't have one originally can contribute to cracking problems, too) And if memory serves, the front driveshaft can't clear the pan on an E4OD. And you need to plug the speedometer port. And buy new yokes for each output, since they'll be 1310 front and 1330 rear, and you'll probably need 1330 Ford front and a flange in the rear.

But yeah, swapping in a manual-shift 1356 or 208 is easy and cheap. Just need to make sure that your donor t-case isn't worn out (shift forks, oil pump, planetary end play, etc). I even know where a good-condition 1356 is, too... no shifter, though. And you'd have to get it from Raleigh. ;)
 
yeah, the guys at advance adapters said i would have to grind a notch in the tail housing, but didn't say anything about cracking the tranny(witch wouldn't hurt to be rebuilt also) that"s good info. thanks shaun. anyways, the next question was going to be twin stick or not? i see there's a couple different styles, the stainless, which would be great for an older model, or the cable type twin stick conversion. im not personally sure but it looks like it could be used without having to grind a notch in the case. i have also failed to mention that i have 3/4 ton 44/60 axles i am wanting to swap in. i also have most parts from a donor truck that i could use. im sure there is going to have to be some fabrication work and trial and error also. hell, maybe i should just stick with the classic fords
 
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