ZF5 with 205 transfer case

[Adam7118]

Hey guys. I'm putting a coyote motor in my 67 with a ZF5. I was originally going to do the Dana 20 with the adapter from advanced adapters but it looks like I can find a 205 cheaper. The 205 wouldn't require an upgraded output shaft either. Do you think I'll run into fitment issues?

 

[phred]

The 204 will bolt up to the zf but you will need to notch the tail housing on the zf to clear the shift linkage for the 205. Also the 205 is heavy and the tail housing on the zf is weak. Make sure you make a solid crossmember to support the 205. Don’t rely on the zf to carry the load.
Here are some photos of the notch and a truss I made to reinforce the tail housing.

 

[Adam7118]

This is exactly what I was looking for. Thank you! Did you have any issues with the 205 and the frame? Also, will any year 205 fit? BTW very nice work. The truss is very nicely done. Did the truss eliminate the need to do a crossmember on the frame:?

 

[1969]

It should clear your frame but just barely. I am going the same route with a ZF5 and NP205.
You’ll want a Ford married 205.

 

[phred]

Thanks, After all the work rebuilding the zf and getting in the truck that last thing I wanted to happen was for the tail housing to crack. The photos you see are for putting the zf in a 78 bronco. The ‘78 a lot heavier than an eb so the truss is just insurance against the added torque necessary to move the heavier truck. The 205 still needs the crossmember. Even when the bolted to the strong np435 ford but a second support on the 205 in the full size broncos

 

[Adam7118]

Thanks guys!