Can't Get Enough
Join Date: Sep 1999
Location: Cotopaxi, Colorado
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Re: One more question, dual transfer case question
I already picked up three 203's for free from a friend at a local yard. I pulled all of them apart and sent the shafts to Moser for resplining. I also sent them the input shaft from the 300, so they would know what I was trying to do and make the resplinine correct. I deliberatly will have them splined a little longer than what will be needed, so I can just cut to the proper length.
One of these boxes will be a direct bolt to a 435, so there shouldn't be any adapters needed to the tranny side, and keep the original clocking. The other, which is from a dodge, will be attached to NV-4500. This one will be clocked about 90 degrees, so the shift slector will point straight up. I think that I can make linkage that will use the Dana 300's shift tower, and just add a twin stick design, but only use the second lever for the front case. I will have to drill an oil galley in the input retainer to match the original. The dodge 203 uses the circular 6 bolt pattern which is very close to the NV-4500, so redrilling the the extension housing of the NV-4500 shouldn't be a problem. I can't find a 203 case that has the same spline count as the 28 on the lightweight NV-4500 yet, I am still looking. I may have to have the larger NV-4500 (32 spline) spline output shaft cut to match, since I already have the shaft from a Chevy's NV-4500 from a core. The third 203 I have I am trying to just make a sandwich that will bolt in between another stock 203 (input and output the same)
The actual flat adapter plate that will go between the 300 and the 203 will be made by an unemployed machinest friend of mine (he made mountain bikes for a living) from a 2 inch thick piece of flat aluminum I found in a recycling yard for $85. I don't think that I have to worry about any sealing problems between the two cases, because Dana 300 has it's own input seal, the Dana 20 is a different story.
If I ever get any of these to work, I will post the results. I am not in any hurry, and plan on this as being a winter project.