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i have a 77 chevy 3/4 ton 4wd p/u. I was just wondering if a newer (1980 or so) gear driven transfercase will interchange with my aluminum housed chain drive transfer case. The p/u had a manual tranny in it from the factory, but it now has a 3 speed auto. I don't know if the transfer case is the original or not. I just wanted a sturdier transfer case for pulling heavy loads in 4wd because the one in the p/u is jumping under a load. I will take any input on this project. thx
 

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You probably won't find a gear drive in an newer pickup. The NP205, gear drive was used until 79, when the NP 208, aluminum chain drive replaced it. I've seen a very few 1 ton's, with NP 205's, later.
I almost bought an 88 old body style 1ton 4x4, years ago. It was a TBI 350, SM465, with what looked like a NP205.

I'm amazed you have a 208, in your 77. It wasn't changed, from a NP203 full time, was it?

If you find a NP205, you will need the adapter and sleeve, too. The NP208 has a snout on the input, to couple with the trans. The NP205 has a longer adapter, with a sleeve between the shafts. Be careful you get one from an auto, because the manual runs coarse splines.
 

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Your 77 Chevy 3/4-ton should have come from the factory with EITHER a TH-350 OR TH-400 transmission, a NP-203 full time chain driven transfer case, a Dana 44HD front axle, and a "corporate" 14 bolt full floating rear axle.

You are more able to adapt a 205 transfer case to whichever transmission you have, currently if you have the 350 transmission and find a cheap 205 T-case from behind the 400 transmission or 465 manual transmission, IT WILL NOT WORK because of the input shaft spline count and shaft size differences between the three transmissions. And vise-versa.

The 205 was installed behind ALL of these transmissions at one time or another, mostly before the NP-203 came around in 1973.
There are also a couple companies now offering adapter kits to swap the 205 into vehicles that did not originally come with it.
Advance Adapters MAY have something to offer, BUT,
Novak has many adapters for many different applications and would be more likely to have what you need, you just need to first determine which transmission you have first. And thats easy enough.
 
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