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Unread 12-17-2013, 12:20 PM   #1
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Join Date: Dec 2013
Location: Lexington, Massachusetts
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YJ Project - Trannies to T-case


First off, I'm a complete dunce in the realm of off road. I know very little of the various tried and tested components but trying to absorb everything so beer with me.

Picked up my first Jeep, 87 YJ, a couple weeks ago and ready to start rebuilding. It came with a rebuilt 4.2l, np435, twin stick np205, d44 front, ford 9" rear, detroit lockers, and some other goodies. So, I'm going to take the 4.2 out and put in a cummins, now my question has to do with marrying a new tranny to the 205.. I've read countless articles and threads of builds and mods, but some are incomplete or have some variation that's not applicable.

I'm considering an NV4500 or the G56, but the nv4500 is alot cheaper so leaning toward that. I have the ford 205, counted 31 splines on the trans output. if I want to use the nv4500 and my 205 i think I only have a few options

1. buy the AA adapter kit w/ the spud shaft and shorten the nv4500 output shaft (http://www.northwestfab.com/Dodge-NV...ter_p_251.html)

Does anyone have experience with this? Would the spud shaft be able to handle the cummins torque?

2. Install 29 spline female input in the 205. I believe the proper dodge 205 had the small bearing

I'm not crazy about the adapter as I have to shorten the trans output, but I have read posts of people using the adapters with success if I must. Thanks for your inputs

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Unread 12-18-2013, 10:29 PM   #2
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1977 CJ7 
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Location: Greenville, North Carolina
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Why not get a tcase that will mate to the nv4500?
77 CJ-7- AMC 360, Edelbrock cam, MC2100, Fenderwells, CJ T18/D20, Chevy D44/EB 9" rear, Trutrac f/r, 4.11, SOA, 1.25 lift shackles, 35x12.50 BFG KM2s, Shackle Reversal
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Unread 12-21-2013, 10:56 AM   #3
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1993 YJ Wrangler 
Join Date: Jan 2005
Location: Albuquerque, NM
Posts: 6,490
Originally Posted by Dunce View Post
Hi, First off, I'm a complete dunce in the realm of off road.
In that case, why in the frell are you thinking of changing things before you even know what you're doing with the Jeep or what it's weaknesses may be? It sound's pretty decent the way it is.
'93 YJ, '02 GM 4.3 Vortec V6, SOA, dual ARB's, 8.8+D30(w/WarnHubs), 4.88 gears, 35" BFG KM2's, AX15, 15x7 wheels, NP231+4:1+SYE+2LO, York OBA, Warn M8000, no top or doors Apr-Oct.
Member and Web guy: New Mexico 4 Wheelers My Truck Page on NM4W Site
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Unread 12-22-2013, 08:34 AM   #4
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1984 XJ Cherokee 
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Jeep sounds solid as is. Don't go all overboard on the first round. Wheel it, or spend time getting it to wheel before you swap engines and all that. Second, as much as a Cummins sounds fun it has its place, in the tow rig. If you have more dollars than sense you'll end up in the middle of "I wish it was simple". If anything, engine wise, I'd fund a 4.0 engine and a HO harness and upgrade to obd1 and build a stroker.

4.2 is solid, as is the trans/case you have. Keep and wheel it.
84 xj 350tbi, sm465, 203/205, 60/70. links and other junk.
what size sawzall blades does it take to fit 40's?
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Unread 12-27-2013, 06:31 AM   #5
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yea jp, that was the easiest path; I picked up a 29 spline 205 that'll bolt right up to the 4500. I have to upgrade to the d60 front anyways so switching to a passenger drop isn't a problem. I'll save my ford 205 for another project.

I bought it to do the diesel swap, cause I can and it's what I want. It was a solid wheeling rig but it sat for some time and needed some rebuilding
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