New Process (NP) 271 Transfer Case

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:

Transfer Cases

Ford Dana 20 Transfer Case:

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

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.

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.

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 Transfer Case:

Type: Part-time, aluminum, chaindriven case.

Low range: 2.74:1

1980 – 1988 Ford F-series

1980 – 1989 Ford Bronco

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

BW1356 Transfer Case:

Type: Part-time, magnesium, chaindriven case

Low range: 2.69:1

1987 – 1997 Ford F-series, Bronco

  

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 Transfer Case:

Type: Cast aluminum case, Drive Type: Chain drive, manual & electronic shift versions. Available as part time or fill time, torque-on-demand

Gear Ratios:

  • High Range 1.00 : 1 (direct drive)
  • Low Range 2.64 : 1

Fluid Type/Spec: Automatic transmission fluid (ATF), 4 pint (1.9 liter) capacity

Weight: 98 lbs dry

1996 – 2003 Ford F150/F250, Expedition

 

BW4407 Transfer Case:

Type: Magnesium case, chain drive, part time, PTO available for F350, manual & electronic shift versions

Gear Ratios:

  • High Range 1.00 : 1 (direct drive)
  • Low Range 2.69 : 1

Fluid Type/Spec: Automatic transmission fluid (ATF), 2 liter capacity

1996 – 1998 Ford F250/F350

 

BW4416 Transfer Case:

Selectable torque on demand system, 2H-A4WD-4H-4L

Low range: 2.64:1

2003 – 2004 Ford F150

2001 – 2005 Ford Expedition

2001 – 2005 Lincoln Navigator

 

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

NP203 Transfer Case:

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.

1974-1979 Ford Fullsize

 

NP205 Transfer Case:

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.

1973-1979 Ford Full Size

 

NP208 Transfer Case:

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 Transfer Case:

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

Low range: 2.72:1

NP273 Transfer Case:

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

Low range: 2.72:1

Ford Transfer Case Applications:

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
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