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Fullsize Ford Truck Transfer Cases

Looking for information on transfer cases found in fullsize Ford trucks?

This page is dedicated to those cases and provides a list of vehicles, a list of cases that were found in them, and photos for reference.

Identification:

Here is an example of the Borg Warner (BW) and New Process Gear (NP) identification tags:

Borg Warner:

New Process:

Ford Dana 20:

Type: Part-time, cast-iron, geardriven case

Why you want it: Early Bronco versions have a strong housing, are small and lightweight, and can handle a fair amount of torque. 

Why you don't: The Bronco versions may be difficult to find. The Jeep Dana 20 and Ford Bronco Dana 20 are not the same.

The Ford Dana 20 transfer case is gear driven with a cast iron case. It was used in early Broncos from 1966 until 1977 and it was used in some Ford pickups. It is drivers drop and it was available with a couple different low range ratios.

Bronco Dana 20: 1966-1972 - These cases had a 2.46:1 low range. 

Bronco Dana 20: 1973-1977 - These cases had a 2:34:1 Low range

   

 

BW1345:

Type: Part-time, aluminum, chaindriven case.

Low range: 2.74:1

Note that the BW1345 has more 'ribs' in the case than the BW1356.

 

BW1356:

Type: Part-time, magnesium, chaindriven case

Low range: 2.69:1

 

Rare PTO-style BW1356 from a diesel pickup. Note the front case half is aluminum on this version, while the rear is magnesium, like all other BW1356s.

BW4406:

 

BW4407:

 

BW4416:

 

Can't tell the difference between the BW4406 and BW4416 transfer case? Try looking for the gusset here:

NP203:

Type: Full-time four-wheel- drive, cast-iron, chaindriven case

Low Range reduction ratio: 1.96:1 High Range: Direct (1:1)

Why you want it: Its full-time and easy to find, and its housing is made from heavy-duty cast iron.

Why you don't: It weighs 170 pounds. The components may need to be replaced due to overuse. Over time, the full-time four-wheel drive could wear out other components.

The Ford NP203 has a 31 spline female input. The bolt pattern is the Ford rotation of the 6 bolt circular bolt pattern.

   

NP205:

Type: Part-time, cast-iron, geardriven case

Low range: 1.96:1

Why you want it: One of the burliest transfer cases ever built. Made with both right- and left hand outputs, and divorced versions. It is heavy-duty, geardriven, and relatively easy to find. The 205 is available in six different versions.

Why you don't: The low range is an anorexic 1:96.1. The 205 may not be shift-on-the-fly for some, and confusion may exist because there are six versions. Additionally, some have a slip-yoke on the rear output.

   

 

NP208:

Type: Part-time, aluminum, chaindriven case

Low range: 2.61:1

Why you want it: The 208 is lightweight, the chain- drive operates quieter, and it is shift-on-the-fly. Two additional perks are that the case is inexpensive and easy to find.

Why you don't: Weak slip-yoke design, aluminum housing may crack, removing the rear driveshaft causes an oil waterfall (Dodge and Jeep versions have bolt-on yokes), and several versions exist.

 

 

NP271:

NVG271 (manual shifter) NVG273 (electronic shifter) Type: Part-time, magnesium, chaindriven case.

Low range: 2.72:1

 

NP273:

NVG271 (manual shifter) NVG273 (electronic shifter) Type: Part-time, magnesium, chaindriven case.

Low range: 2.72:1

 

 

Bronco Full Size 1989-1996 BW1356 (Electric shift) rear circular flange front fixed yoke
  1989-1996 BW1356 (Manual shift) rear circular flange, front fixed yoke one piece shift linkage
  1987-1989 BW1356 (Electric shift) front and rear fixed yokes
  1987-1989 BW1356 (Manual shift) fixed front and rear yoke bolt on shift linkage
  1987-1989 BW1356 (Manual shift) fixed front yoke rear circular flange bolt on shift linkage
  1987-1989 BW1356 (Manual shift) front and rear fixed yokes one piece shift linkage, 2" rear spline
  1982-1989 BW1345 31 Spline front input front and rear fixed yokes shift lever is downward parallel to case when in neutral, .875 speedo hole
  1980-1986 NP208F 31 Spline front input non-synchronized front & rear fixed yoke
  1976-1979 NP203F Remote mount, full time, three fixed yokes
  1973-1979 NP203F 31 Spline's front input married, full time, automatic transmission
  1973-1979 NP203F 4 speed, married, full time
  1976-1977 NP205F Three fixed yokes remote mount, part time, w/manual transmission
Excursion 2003-2005 NP273F 34 spline input gear super duty (electric shift) w/o speedo hole, 5 speed automatic ZF trans
  2000-2005 NP273F 31 Spline front input shaft super duty, (electric shift) automatic & manual w/speedo hole
Expedition 2005 BW4416 31 Spline input, rear slip w/TOD w/o speedo hole, electric shift, mounting hole in front case half
  2002-2004 BW4416 31 Spline input, rear slip w/TOD w/o speedo hole, electric shift,
  1999-2002 BW4406 (W/torque on demand) (electric shift) front & rear sensor hole w/o speedo hole
  1997-1998 BW4406 (W/torque on demand) (electric shift) with speedo hole, front & rear sensor
F100 150 Series Pickup 2003-2004 BW4416 31 spline input, rear slip, w/o TOD, w/o speedo hole (electric shift)
  1999-2005 BW4406 (W/o Torque on Demand) (electric shift) w/o speedo hole
  1999-2005 BW4406 (W/o Torque on Demand) (manual shift) shift on fly, w/speed sensor hole
  1997-1998 BW4406 (W/o Torque on Demand) (electric shift) with speedo hole, front and rear sensor
  1996-1998 BW4406 (W/o Torque on Demand) (electric shift) with speedo hole
  1996-1998 BW4406 (W/o Torque on Demand) (manual shift) w/speedo hole shift on fly
  1991-1997 BW1356 (Electric shift) w/o PTO slip rear yoke
  19891997 BW1356 (Manual shaft), w/o PTO slip yoke, one piece shift linkage
  1988-1991 BW1345 32 Spline front input front & rear fixed yoke shift lever upward, parallel to front face of case in neutral .875" speedo hole
  1987-1988 BW1356 (Manual shift) w/o PTO slip rear yoke bolt on shift linkage
  1987-1988 BW1356 (Manual shift) w/PTO, slip rear yoke bolt on shift linkage with PTO
  1982-1989 BW1345 31 Spline front input front and rear fixed yokes shift lever is downward parallel to case when in neutral .875 speed hole
  1980-1986 NP208F 31 Spline front input non-synchronized slip rear yoke
  1977-1979 NP205F 31 Spline front input married, part time, C-6 automatic fixed front and rear output yokes
  1976-1979 NP203F Remount mount, full time, three fixed yokes
  1973-1979 NP203F 31 Spline front input married, full time, automatic transmission
  1987-88 NP205F Three fixed yokes remote mount, part time, w/manual transmission
F250 Series Pickup 1999 BW4406 (W/o torque on demand) (electric shift) w/o speedo hole
  1999 BW4406 (W/o torque on demand) (manual shift) shift on the fly, w/speed sensor hole
  1997-1998 BW4406 (W/o torque on demand) (electric shift) w/speedo hole , front & rear sensor
  1996-1998 BW4406 (W/o torque on demand) (electric shift) w/speedo hole
  1996-1998 BW4406 (W/o torque on demand) (manual shift) w/speedo hole, shift on the fly
  1996-1997 BW4407 W/O PTO (manual shift)
  1991-1997 BW1356 (Electric shift) w/o PTO slip rear yoke
  1989-1997 BW1356 (Manual shift) w/o PTO slip rear yoke bolt on shift linkage
  1989-1997 BW1356 (Manual shift) w/o PTO slip rear yoke bolt on shift linkage
  1988-1991 BW1345 32 Spline front input front & rear fixed yoke shift lever upward, parallel to front face of case in neutral .875" speedo hole
  1987-1988 BW1356 (Manual shift) w/o PTO slip rear yoke bolt on shift linkage
  1987-1988 BW1356 (Manual shift) w/o PTO slip rear yoke bolt on shift linkage with PTO
  1982-1989 BW1345 31 Spline front input front and rear fixed yokes shift lever is downward parallel to case when in neutral 2" speedo hole
  1980-1986 NP208F 31 Spline front input married, part time, C-6 automatic fixed front and rear output yokes
  1977-79 NP205F 31 Spline front front input married, part time, C-6 automatic fixed front and rear output yokes
  1976-1979 NP203F Remote Mount, full time three fixed yokes
  1973-1979 NP203F 31 Spline's front input married, full time, automatic transmission
  1973-1979 NP203F 4 speed, married, full time
  1976-1977 NP205F Three fixed yokes remote mount, part time, w/manual transmission
F-350 Series Pickup 1994-1997 BW4407 W/PTO (manual shift) w/o emergency brake
  1989-1997 BW1356 (Manual shift), w/PTO slip rear yoke, one piece shift linkage
  1987-1988 BW1356 (Manual shift), w/PTO slip rear yoke bolt on, shift linkage with PTO
  1980-1986 NP208F 31 Spline front input non-synchronized slip rear yoke
  1977-1979 NP205F 31 Spline front input married, part time, C-6 automatic fixed front and rear output yokes
  1976-1979 NP203F Remote mount, full time, three fixed yokes
  1973-1979 NP203F 31 Spline front input married, full time, auto transmission
  1976-1977 NP205F Three fixed yokes remote mount, part time. w/manual transmission
Motor Home Ford Chassis 1999 BW1356 Manual shift, w/o PTO, slip rear yoke bolt on shift linkage, w/o rear extension housing
F Series Super Duty 250 350 450 550 1999-2005 NP273 24 Spline front input shaft super duty (electric shift) manual 6 speed transmission w//o speedo hole
  1999-2005 NP271 24 Spline front input shaft super duty (manual shift) manual 6 speed transmission w//o speedo hole
  2003-2005 NP271 34 spline input gear super duty electric shift w/o speedo hole, 5 speed automatic ZF
  2003-2005 NP273 34 spline input gear super duty electric shift w/o speedo hole, 5 speed automatic transmission
  1999-2003 NP271 31 Spline front input shaft super duty (manual shift) auto or manual transmission 5 speed w/o speedo hole
  1999-2003 NP273 31 Spline front input shaft, super duty (electric shift) auto or manual transmission 5 speed w/o speedo hole

 

   

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