Got 2 new transfercases today

[FordGuy100]

Is welding cast aluminum easier than say, cast iron? Just out of curiosity...

 

[MUDKICKR]

your best bet is to tig it. you can mig it but you would be better off to tig it.

 

[FordGuy100]

Well when I think of welding aluminum I automatically think of Tig welding. I'm mediocre at best Tig welding aluminum and was just wondering if cast aluminum was any harder to weld.

 

[MUDKICKR]

welds just fine. ive been around a lot of rockbuggies here lately and have seen some good and bad jobs done. but i helped on one and it worked like a charm. i know here soon i will be cutting up a 203 to use on my trk. something i would really like to do is get a 203 out of a chevy (pass side drop) and make it where i could use it like some kind of pto for a air compressor or something. (but the frt transfer case would have to be setup for a fwd option, which i have seen done)

 

[BigRigTech]

Here's a 2wd ZF hooked to a divorced 205....This is what I did under my truck, Makes pulling the tranny a breeze. I've had both styles of 205's and I think a married 205 from a C6 should bolt right on to a ZF.

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[tractorman86]

hey big red isnt that a 2wd ZF? nice setup though

 

[BigRigTech]

Yep, a 2wd ZF with a Spicer HD stub shaft. I had a married 205 off a C6 but I traded it for another divorced 205...Now I have 2 divorced 205 spares....Like I need spares anyways.......I can take the transmission out without touching the t-case or the front shaft....The only bad part about a 205 is shifting them into gear - they can be a ***** to get into 4H.

 

[tractorman86]

yea i realized you already said that after i posted, my bad. wanna get rid of a spare?

 

[BigRigTech]

Not really, took me months to round them up....

 

[tractorman86]

well i guess it was worth a try

 

[Diesile]

On my '86 F350 w/ZF5 (4x4) I was going to mate the 205 from the T19 I had to the ZF5. Everything is a goes except for one rib on the ZF case that would have to be ground off to allow clearance for the shifting rods. I was assured that this is not a problem for the ZF5.

 

[MUDKICKR]

hey bigrigtech, i bet it is hard to get your transfer case into gear. hell i mean first you have to set the parking brk, then get out of your trk, then you have to climb under your trk and then you have to move it without a shifter. good pics though.

 

[freebird01]

i guess you guys are missing the big picture. take the bw1354 and remove the frt output shaft and chain. cut the case (where the frt output was) as close to the gear case as possible without cutting to much on each case half. weld alum plate where you removed the frt output shaft. put halves back together and seal it up. install to transmission and there you have another low range. also it lets you keep your 4x4 transmission and run a divorced mount transfer case.
i am in the process of doing this setup on my trk. but im using a 203 mounted to my zf5, with a divorced mount 205. also i will have three shifters just for my transfer cases.

thats the hard way to do it...you can buy the adapter to go from a 203 to a 205 and make it one unit...makes for one HEAVY unit...but a cleaner install