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