np205 fit issues?

[bwjohn]

someone recently told me that there are some fit issues with the np205.

namely it doesn't fit between the frame, is this the case? what mods if any need to be made there?

Also, they suggested that the gearing is actually not that great? thoughts?

thanks for the info, brandon

 

[DEEPWOODS]

It will fit between the frame , yes the low gear is a bit higher

 

[sykanr0ng]

Fit between the frame rails?
Yes, without modifications.

Gearing?
Low range is only 1.96 to 1, and there is no low gear set made for the Ford version.
Your only option for lower gearing is a doubler gearbox, those add several inches of length to the drivetrain.

The other issues are:
It is heavy so needs extra support.
If you use it with modern Ford round mounting flange transmission a notch needs to be cut in the flange to clear one of the shift rails.

 

[TFD32]

Yes, it will fit. Gearing is a little bit higher.

 

[DirtDonk]

How much of a concern is the low ratio vs the strength?
What transmission and tire size and gear ratios will you be running?
And are you planning to do much off-roading in the first place? I assume maybe yes, due to the fact that you're actually installing a 205, but you could be doing it for some other reason.

Good luck.

Paul

 

[sykanr0ng]

Not only how much off-roading but also what kind?

Sand dunes or mud don't need as low of a low range as rock crawling, and the extra strength of an NP205 could help with the higher speeds in sand or mud.

 

[pcf_mark]

It's fat and it's heavy but it fits. Bomb proof. Bolts right up to a 4R70W (grind a notch in the adapter). You can re-seal it for $20. You need to make a custom mount to support after the transmission because it is heavy.

I only drive on road and in snow and only use 4W high so I can't speed to how low gear is.

 

[SavageBurro]

Not directly responsive to your questions but I thought I'd throw this out there.

I don't have first hand experience with these reduction / adapter setups but I am pretty sure they are not much longer (if at all) than stock and provide solutions to mediocre np205 gearing. Result is a very strong tcase that should fit nicely length-wise and provide great gearing options. allows you to select 1:1 or 2.72 or 1.96 or 5.33 in a short 1 ton package.


There are quite a few write-ups on np205 installs in early broncos. I recommend using the search on this site or googling, "early bronco np205". I don't say that to be flippant - just to let you know you will get lots of great pics, write-ups etc.

One of these is on my list of upgrades next year. Each company (and others) also do a standard 'doubler' that is a bit cheaper but they end up a bit longer.

http://www.northwestfab.com/Titan-Series-NP205-BlackBox-i_p_2402.html

http://offroaddesign.com/catalog/Magnum Box.htm

http://www.behemothdrivetrain.com/np205-strong-box-shorty.html

 

[bwjohn]

I want to be capable off road, do i rock crawl? No.

Right know i have 33 tires.

Stock gears, haven’t researched gears yet to make up my mind.

I was telling this person my plan to rebuild orginial engine, attach 4r70w which i just bought and bolt it to the 205. He shot big holes in the whole thing.

So i am rethinking the whole thing. I was in the process of just collecting parts and getting ready to start at the turn of the year.

Thanks for all of the info
Brandon

 

[sanndmann3]

I've got 351W (E.DI.S. by EFI Guy), 4R70W and NP205. No holes in my powertrain... ;D
You will want to regear for sure. I'm running 35" tires and considering going from 4.56 to 5.14s over the winter...

Its past my bedtime so I will post more tomorrow. You will need a custom cross member but everything else pretty much bolts up...

 

[buckenbronco]

I've got 351W (E.DI.S. by EFI Guy), 4R70W and NP205. No holes in my powertrain... ;D
You will want to regear for sure. I'm running 35" tires and considering going from 4.56 to 5.14s over the winter...

Its past my bedtime so I will post more tomorrow. You will need a custom cross member but everything else pretty much bolts up...

Hey sandman I’m getting ready to put the same setup in my truck. Do you have any pics of the cross member that you built? Also where shifter came up through. Thanks

 

[sanndmann3]

1st post is mod required for the adapter housing (Explorer). Can see the cut away material at the bottom of the 1st pic. Its pretty straight forward.

 

[sanndmann3]

2nd post is cross member fab...

Used a harbor freight pipe bender and 1 3/8 tube ( fit one of the dies real nice)
filled the tube with sand and it bent pretty nice...

 

[sanndmann3]

Last set is the 205 installed in the truck. In addition to the custom cross member, I made another support that ties into the inspection cover. Used a thicker piece of stock to replace the cover... I also used the factory mount for the 205 on the drivers side rear.

The 205 is about 30-40 pounds heavier than the Dana 20. In my opinion, you want more support for the 205 more due to the aluminum adapter housing and the tiny metric screws...

Probably leaving out details... any questions, fire away!

 

[bwjohn]

what about exhaust going around the 205?

 

[buckenbronco]

What about the shifter setup on the inside.

 

[sanndmann3]

My exhaust is custom. the mufflers are outside the frame rails and it dumps in front of the rear tires. I've read on here that you can clock the 205 to make room for more conventional routing... no 1st hand experience though...

For the shifters, they are pretty much in the same location. My access hole has been opened up over the years... working on an aluminum cover plate... another partially done project.

 

[pcf_mark]

You can use the stock Ford unit just cut to length. I think I needed to make my hole longer but not wider.

 

[buckenbronco]

Do you think it matters on which headers you use

 

[DirtDonk]

...Right know i have 33 tires.
Stock gears, haven’t researched gears yet to make up my mind.

Stock could be either 3.50-ish or 4.11-ish. The 4.11's would be just the minimum for 33's, much less an overdrive. But with the right engine that combo is actually pretty good for most of what we do with our rigs these days.

I was telling this person my plan to rebuild orginial engine, attach 4r70w which i just bought and bolt it to the 205. He shot big holes in the whole thing.

Like what size holes?;D
But really, what did he say that got you thinking you were heading in the wrong direction?

They might be right of course, but curious to see if we all agree.

Paul