View Full Version : Transfer case swap

Claveland 4x4
11-12-2006, 01:14 PM
Right now ive got a 208 bolted to my AOD, can i bolt on a 205 in its place? My concerns are with the output shaft length and spline count.. Im going to pull it off in the spring and put them side by side to see but for now i thought i'd ask around to see if anyone knew from experience. :confused:

11-13-2006, 09:24 AM
It should work.
The closes swaps I have done like this;

79 F250, 429CJ to a ZF 5 speed to a NP205. Bolted up no prob. All we had to do was make a new cross member, drive shaft mods & make the floor hump bigger.

'86 F250, 6.9 Diesel, BW 4 speed, to a NP205 (had a 208) . No problems, just cross member & shaft mods.

11-13-2006, 12:20 PM
Im assuming you have either a FS Bronco or F-150, heres some links for ya with info on ZF 5spd swaps, theres info in them to about T-Case swaps also




11-13-2006, 02:25 PM
He's got himself a 78 F-150, 351C/AOD

FU Toolbag
11-14-2006, 02:29 AM
you probably have a bgorg warner in your truck. It looks like a 208, but it's a lot stronger. It should hold most mnotors you put in front of it, in fact the tranny should blow before it does. If you want to put a 205 on it anyways you will have driveshaft problems as the 205 has the front driveshaft closer to the tranny than the b.w. The front axle on the older solid axle f150's has the pumpkin further outbord. this difference allows the narrower 205 and a c6 combo work. I tried a 205 and c6 combo on our 81 bronko, and the driveshaft was in full contact with the tranny. I know the aod 4 is bigger still than the c6. Also, you'll need to change driveshafts, probably custom ones. Just a lot easier to leave it alone.
Goddamit, I think my wife is writing this one.

Claveland 4x4
11-14-2006, 07:11 PM
Thanks guys :D

Just to clarify, like Wagoneer said ive got a 78 F150 with a mild '71 351C, and an '86 AOD and 208 combo from my previous truck. I'm planning on some power upgrades, and even tho the 208 was rebuilt and updated with some better parts, its going to blow up sooner or later! Not to mention since the frames is narrower in a '78 than an '86, the tcase hits the frame edge. It also sits too high and hits the underside of the truck a little but that could be remedied with some tranny mount/crossmember alterations. If anyone wants to know whats involved in installing these parts feel free to ask, its easier than you think and the 4th tranny gear is nice if youve got steep diff gears!

lol okor... ive got plenty of parts trucks and i like a challenge plus ive got a good reasonable priced driveshaft guy so any changes are easily dealt with.

FU Toolbag
11-15-2006, 09:56 AM
What did you do about the brain for the aod4

In The Zone
11-15-2006, 10:08 AM
go stick and loose the aod as well why go with a 205 unless u are going to address the shitty low range ratio....

11-17-2006, 11:19 AM
What did you do about the brain for the aod4

There isn't one, it's a non electronic AOD.