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4. Ford New Process 205/208

Full size Ford trucks have never been a very popular truck for transmission upgrades. Over the years, we’ve only had a few requests for certain adapters. Most of the early Ford trucks produced had either a single gear ratio Dana 21 transfer case or they had a divorced New Process transfer case. The Dana 21 was very light-duty and, therefore, not very popular to adapt to. The divorced New Process transfer cases were good gear boxes; however, no adapters were required when changing transmissions, just a custom driveshaft did the job.


Around 1974, the first Ford married transfer cases came on the scene. From 1974 to 1979, both the NP205 & NP203 transfer cases were found in Ford trucks. Both New Process transfer cases used a 31 spline input; however, the bolt patterns were different. Since the NP203 was discontinued in 1979, we have never made any adapters for this transfer case. In 1980, Ford changed transfer cases to the New Process 208 and the 6 bolt Borg Warner transfer cases. At that time, Ford still offered the NP205 on special order applications. The transfer cases (NP205, NP208, and the 6 bolt B/W transfer case) found in these vehicles are all basically treated the same when it comes to adapting to them. They all have a circular 6 bolt pattern, a 31 spline input, and the same index diameter. The New Process 205 has one difference that does play a part with our adapters. The adapter requires a clearance notch for the stock transfer case shifter linkage. Since these Ford transfer cases all have the same basic configuration, the task of swapping a Ford 4WD transmission with another Ford 4WD transmission can normally be accomplished with the stock adapter.

The adapters we manufacture are designed to couple the different Chevy automatic transmissions and the NV4500 5 speed transmissions to the Ford transfer cases. We’ve also designed bellhousing adapters to couple the Chevy automatics and the NV4500 transmission to the stock Ford engines. (Note: In reference to the transfer case adapters, we have seen different transmission output shaft stickouts on the Fords. The transfer case adapters we manufacture are designed around a 1” long stickout from the adapter. If your stock transmission had a flush output shaft stickout, then our kit may require the shaft to be shortened accordingly or a spacer plate to be used).

 

All Ford versions had fixed rear output shaft 32 spline and 32 spline front output shaft.  


 

 

FORD TRUCK BELLHOUSING ADAPTERS:

P/N 712588-A GM automatic to Ford 302 bhsg. adapter plate (28 oz. balance)
P/N 712588-B GM automatic to Ford 302 bhsg. adapter plate (50 oz. balance)

P/N 712551 - Dodge NV4500 & TR-4050 adapter plate to standard Ford bhsg. (4.848” index)
P/N 712549 - GM engine to Ford transmission (Full bellhousing)


FORD TRUCK TRANSFER CASE ADAPTERS:

700R or 4L60E to NP205 / NP208 / B.W.:

The kit comes with a new output shaft that must be installed into the transmission. We then uses a 31 spline spud shaft supported with a bearing in the adapter to couple to the transfer case.
P/N 50-6904 - GM 700R to Ford NP transfer case adapter. 3.625" long
P/N 50-6924 - GM 4L60E to Ford NP transfer case adapter. 5.125" long


TH350 to NP205 / NP208 / B.W.:

This adapter is 3.625” long. The kit comes with a new output shaft that must be installed into the transmission. We then uses a 31 spline spud shaft supported with a bearing in the adapter to couple to the transfer case.
P/N 50-6908 - GM TH350 to Ford NP transfer case adapter.


TH400 2WD to NP205:

This kit uses a stock 2WD output shaft. The Ford NP205 has a 31 spl. input and the kit comes with a new 32 spl. input that must be installed. Once the new input is installed the Stock TH400 shaft will couple the two together.
P/N 50-3204 - GM TH400 2WD to Ford NP205. Adapter housings is 4.25” long.


TH400 4WD to NP205 / NP208 / B.W.:

This kit uses the TH400 with a 2.4" output stickout from the rear of the case. The shaft will need to be shortend before installing the adapter. The kit comes with a spud shaft 32 spl. x 31spl. that couples to the shortened 4WD output up to the 31 spline transfer case.
P/N 50-3206 - GM TH400 4WD to Ford NP205 / 208 or B.W. transfer case adapter. Adapter housings is 4.25” long.


4L80E 2WD to NP205:

This kit uses a stock 2WD (full spline) output shaft. The Ford NP205 has a 31 spl. input and the kit comes with a new 32 spl. input that must be installed. Once the new input is installed the Stock 4L80E shaft will couple the two together.
P/N 50-3205 - GM 4L80E 2WD to Ford NP205. Adapter housings is 4.25” long.

GM 6L80 4WD & some 2WD to NP205:

The Ford NP205 has a 31 spl. input and the kit comes with a new 32 spl. input that must be installed. The kit is designed for the 4WD transmission, however, some long splined 2WD transmission can work. the 2Wd outputs must be shortend.
P/N 50-9550B - GM 6L80 32 spl. to Ford NP205 T/C adapter. Adapter is 5.325" long


GM 6L90 4WD to NP205:

The Ford NP205 has a 31 spl. input and the kit comes with a new 29 spl. input that must be installed. The kit is designed for the 4WD transmission, however,we have seen two length of 4WD output shafts. The ideal shaft stickout is approxamatly 3.25".
P/N 50-9550A - GM 6L90 29 spl. to Ford NP205 T/C adapter. Adapter is 4.70" long


NV4500 29 spl. 4WD to NP205:

This adapter is based on the stock Dodge NV4500 4WD with a 29 spline output shaaft. The stock tailhousing is 6.3” long couples to an adapter ring 1". The kit has a new 29 spline input gear that needs to be installed into the Ford transfer case.
P/N 50-9550 - Dodge NV4500 29 spl. to Ford NP205 T/C adapter. Adapter is 7.30" long


NV4500 4WD & TR-4050 to NP205 / NP208 / B.W.:

The adapters listed below use the stock Dodge tailhousing 6.3” coupled to an adapter ring that is1.625”. These are spud shaft kits and one fits the 23 spline Dodge output and the other fits the 29 spline. Both spud shafts have a male 31 spline to fit the stock Ford transfer case.
P/N 50-0207 - Dodge NV4500 23 spl. to Ford NP205 / 208 or B.W. T/C adapter
P/N 50-0220 - Dodge NV4500 29 spl. to Ford NP205 / 208 or B.W. T/C adapter

NV4500 4WD to NP205 Transmission Kit
P/N 27-0040T - Stock Dodge 29 spl. Ford NP205 Ford V8 engine adapter plate. O.A.L. 27.500”

 

6R140 6 Speed Automatic:

These adapter kit allows the 6R140 to be coupled to the Atlas 2 speed transfer case. Adapters are available for either the 2WD or 4WD transmissions with a 43 spline output. Converting a Ford Van or any other 2WD Ford vehicle can now be done with this adapter.

P/N 50-6140 - 6R140 TO 4X4 TO ATLAS
P/N 50-6140 - 6R140 4X4 A.T. (EXTENDED)
P/N 50-6140 - 6R140 4X2 A.T. (EXTENDED) No output shaft modifications

 

NP205 INPUT GEARS:
We manufacture the NP205 input gears. Our gears are a bit different than OE (original equipment) in that they are engineered in a two component design that not only expedites production time, but also reduces material waste & expenses. These two piece gears sets come with the correct snap rings and instructions for installation into any NP205 gear box.

P/N 716044-F -NP205 GEAR FORD 31