NP435 with NP205 or Dana 20?

[zainyD]

Wanted to get everyone's opinion on this. I'm looking to swap in a NP435 in the place of a factory 3 speed. The primary question is related to which transfer case to run, a NP205 or the original Dana 20.

I have both a 2wd (square pattern) and 4wd (A pattern) NP435. I also have both a NP205 and a T-shift pattern (2.46 low) Dana 20.

The NP205 is stronger, but the low range is 0.50 higher than the Dana 20. Additionally, the NP205 bolts right to the 4wd NP435 with the existing adapter. Whereas I would need an adapter to mate the Dana 20 to the NP435 which costs about $400.

I plan on stretching the wheelbase, so driveshafts are a wash.

In my way of thinking the NP435/205 combo is the best way to go cost and strength wise. However, I'd like to hear some input as to your experience either way.

Thanks!

 

[bmc69]

I've run both. I've broken the D20 factory output shaft but never broken one of the aftermarket ones like WH sells.

I've never broken anything in a 205...ever.

 

[WILDHORSES]

In my way of thinking the NP435/205 combo is the best way to go cost and strength wise. However, I'd like to hear some input as to your experience either way.

What you said. Cost and strength. Great combo especially for a crawler.

Jim

 

[Apogee]

I haven't run an NP435/NP205 in an EB, but I have in my '77 F150 for years, and it's a very stout combination that should survive whatever you want to throw at it so long as you keep oil in them most of the time. The granny gear can offset the anemic low range in the 205 to some extent, but can be a bit tough to shift out of since it's not synchronized, especially under load.

 

[sanndmann3]

What are you building the truck for??
I have broke 3 Dana 20s. They do not like high revs in low range, like I run on the sand dunes. Went to a 205 and ended my T case issues. Low range kinda sucked till I re-geared...

 

[txtruk15]

Having run a NP435 with a D20, I'd also ask what you're using it for the most- hardcore rock crawler? good amount of street time? I ended up swapping out the NP435 for a more forigiving and smoother NV3550 and don't regret it all and didn't really need the granny gear from the 435. the NV3550 still gets low enough range plus now i have an overdrive. 3550s aren't that pricey either and don't cost too much to rebuild/refresh and Advance adaptors has the plate for it...

 

[Broncobowsher]

What are the plans for this build? Guessing it will be somewhat serious since you are stretching the wheelbase. But not too serious since you are planning on a stick and a budget build. Engine, axle gears, tire size?

The 205 is strong, well proven. But it is a huge and heavy beast. Fits in a Bronco frame but not by much.

The D20 is a pretty good transfer case. A lot of people have pushed them pretty hard and they live just fine.

My thoughts... If you are trying to get tall gears for the highway and use the transmission for the reduction, that puts a lot more stress on the driveshaft and transfer case. Output shaft worries. But if you are going deep on the axles that puts the gear reduction at the axle and the torque on the output shaft is less. It's not like you are going to be doing full throttle in granny low range (if you really are, ignore this and go for the 205 and tell us what other parts blow up). I am a bit of a fan of the D20

Another thought of going to the 205, add a secondary reduction box and get your gearing. Added wheelbase will allow for the room a lot easier. What you save can be put toward a reduction box (have not kept up with all the options these days)

 

[zainyD]

My initial thoughts are for a weekend wheeler/trail rig. Not much by way of rocks down here in Florida, but there are some. Would be street driven occasionally, probably fewer than a couple thousand miles a year.

Drivetrain would be stock 302/NP435/(either NP205 or Dana 20). Axles will either full-width HP D44/9 with 3.50 gears or Super Duty 1-tons (D60/Sterling) with 4.10 gears. I have both sets of axles on hand now. Ideally, I'd like to stretch the wheelbase 10-14". Tires would be 35-40" depending on what axles I decide to run.

 

[zainyD]

Another thought of going to the 205, add a secondary reduction box and get your gearing. Added wheelbase will allow for the room a lot easier. What you save can be put toward a reduction box (have not kept up with all the options these days)

I've looked at Behemoth secondary reduction boxes to put in front of the NP205. However, if I could find a cheap NP203 I could also do a doubler.

 

[Madgyver]

You can always plan to stuff a 203 in between the np435 and the 205.

 

[Broncobowsher]

With the tire/gearing choice, 205.

 

[Apogee]

What do you need or want a doubler for in Florida if it's never going to see any actual rocks? How much gear reduction can you actually use in sand/mud? I'd go NP435/NP205 with some 4.56 to 5.13 gears depending on tire diameter and crank up the HP/torque on the engine (i.e. 408W stroker).