AOD swap? And why not

[Gatordog]

Is an adapter needed to install the AOD to the Dana 20 transfer case, if so would it be better to go with the transfer case that goes with the AOD so no 600 dollar adapter is needed?

 

[bronconut73]

A 205 would bolt up but you will need a new cross member and drive shaft mods.

For some people the 205 is the perfect choice but for others the 20 is the right case.

 

[Broncobowsher]

The AOD only came with full size transfer cases behind them. Too wide for the Bronco frame. The only bolt on transfer case that can be made to fit in the Bronco frame is an NP205 from the 70's. It is still bigger, much heavier, and not that good of a low range. But is will (almost) bolt right to a 4WD version of an AOD or 4R70W.

 

[Gatordog]

If I go with a AOD/ 4R70 combined with a NP205 will I have to cut a new hole in the floor for the transfer case shifter?

Also, if I go with a AOD/4r70 but go with the Dana 20, will I still need to cut the floor?

 

[Broncobowsher]

Yes and yes.
You might be able to make a one off shifter that uses the stock hole. But generally you make a new hole.

 

[Bart]

If I go with a AOD/ 4R70 combined with a NP205 will I have to cut a new hole in the floor for the transfer case shifter?

Also, if I go with a AOD/4r70 but go with the Dana 20, will I still need to cut the floor?

Contact Jon at JB Fab, he'll be able to advise you on that. As I remember I didn't need to mess with the floor in mounting his stainless shifter (twin sticks). I "think" I had some of the first stick sticks that Jon made way back when. Some years ago I went to the 203/205 t cases and now have three sticks coming out of the floor. Jon is a vendor on this site

 

[bax]

Dont run the AOD unless you put the 4r internal parts in it. The AOD drive drum is weak along with the sun and planetary gears. Who cares about the clutch pack when you keep destroying the drum they fit in.

 

[Steve83]

Frank didn't destroyed his in 10 years, driving 80mph to & from work every day, towing a boat, or towing a 4-dog trailer between states.

 

[bax]

Frank didn't destroyed his in 10 years, driving 80mph to & from work every day, towing a boat, or towing a 4-dog trailer between states.

That's great. I destroyed 2 in a month. Same failure. Could be HP and driving style. Both of mine came apart shifting into second.

 

[Bart]

That's great. I destroyed 2 in a month. Same failure. Could be HP and driving style. Both of mine came apart shifting into second.

It's gotta be your driving style. If your picture on the side of your posts are any indication of what you do. 408 cubic inch engine!! You could also be running a bad ass valve body that pours the "coal to it during up shifts". I had a '57 Ford Ranchero that would bark the tire during "normal" up shifts unless I got off the throttle a little during the shift. Luckily it had a C6 behind a 390 FE motor.
The first couple years of the AOD were weak but Ford changed that. I even have an 84 Thunderbird with an early AOD that hasn't come apart under "normal" driving. The AODE parts in my AOD just give me a better 1st and 2nd gear ratio for crawling. Something we do a lot of. Granted it's very slow (1 to 2 mile per hour) but that could be almost straight up or straight down. Try climb over a 3 to 4 foot bolder from a dead stop. A lot of power applied slowly until the tire(s) in question climb over it.
I'm currently installing a rebuilt 351 Windsor and in the course of that I drained the AOD's oil and it came out looking fine, red and not burnt smelling.
Anyway, all I'm doing is defending the AOD. Also, for what it's worth, I also own a F350 7.3 power stroke diesel that pulls a 40 5th wheel Bronco hauler. A few years ago the torque converter went south. I had the whole trans rebuilt by the best (John Woods Automotive) in Holtville, Ca. He told me that Ford is now importing their drums from China. He (John Woods) would not use that crap and instead installed his own custom made drum rated for 700 h.p.

 

[bax]

If I go with a AOD/ 4R70 combined with a NP205 will I have to cut a new hole in the floor for the transfer case shifter?

Also, if I go with a AOD/4r70 but go with the Dana 20, will I still need to cut the floor?

Stock hole will work with the 205 or the dana 20. Go with the JB fab twin stick shifter

 

[bax]

It's gotta be your driving style. If your picture on the side of your posts are any indication of what you do. 408 cubic inch engine!! You could also be running a bad ass valve body that pours the "coal to it during up shifts". I had a '57 Ford Ranchero that would bark the tire during "normal" up shifts unless I got off the throttle a little during the shift. Luckily it had a C6 behind a 390 FE motor.
The first couple years of the AOD were weak but Ford changed that. I even have an 84 Thunderbird with an early AOD that hasn't come apart under "normal" driving. The AODE parts in my AOD just give me a better 1st and 2nd gear ratio for crawling. Something we do a lot of. Granted it's very slow (1 to 2 mile per hour) but that could be almost straight up or straight down. Try climb over a 3 to 4 foot bolder from a dead stop. A lot of power applied slowly until the tire(s) in question climb over it.
I'm currently installing a rebuilt 351 Windsor and in the course of that I drained the AOD's oil and it came out looking fine, red and not burnt smelling.
Anyway, all I'm doing is defending the AOD. Also, for what it's worth, I also own a F350 7.3 power stroke diesel that pulls a 40 5th wheel Bronco hauler. A few years ago the torque converter went south. I had the whole trans rebuilt by the best (John Woods Automotive) in Holtville, Ca. He told me that Ford is now importing their drums from China. He (John Woods) would not use that crap and instead installed his own custom made drum rated for 700 h.p.

Running a c6 for 7 years now. No problems. Thinking about re doing the truck. Going with a 6r80 next perhaps even a 5.2 if I can get my hands on one

 

[Bart]

Running a c6 for 7 years now. No problems. Thinking about re doing the truck. Going with a 6r80 next perhaps even a 5.2 if I can get my hands on one

C6 is a killer trans for a 3 speed. Good luck on the re-do (engine and trans). I'll stay with my 5.8/AOD/203/205/5.13 setup. It's been good for many years. I also have a '75 Ranger that has a Mustang 5.0 and C4 combo. AOD sitting on the garage floor waiting to bolt up to that and Dana 20. Mall Crawler/light duty off roader (hard top, air conditioning, and most all the bells and whistles). We'll see. I'm also building a '69 Sport for my son and his family. I have my work cut out for me.