I am in the process of building a drive train for my 84 chevy one ton cclb 4x4 drw. I have a 12v cummins(1st gen) mated to a 4x4 nv4500. the problem is the transfercase. everybody talks about using a firstgen 205 but it seems like alot of weight to hang from aluminum housings bolted togather also there extremely pricey... If you can find one. Has anyone tried to build a 241c out of a 80s chevy(that would have the right side drop) with a 29 spline input shaft from a dodge 241d. 241 transfer case looks like it will bolt right to the back of a nv4500 without any adapters and would weigh considerably less.any input would be great. If there is a thread on this already I apoligize. I looked for quite a while and couldnt fond any info about it. Thanks Adam

 

the original transmission that 205 was hanging off of was also an aluminum housing so i dont see why you would have a problem. also a 205 T-case is about the most inexpensive one you can get that is pretty much freaking bullet proof.

 

a 205 other than in a cummins is realisticly priced. but in a cummins with 29 spline 700 plus for a used one is not that cheap. I can get old chevy 241s all day for 100ish. thats why I thought about using a 29 spline input in a 241c. the lighter weight is just a plus. I have always ran 231s in my trucks but my trucks have always been alot lighter (then this build), and never had a problem. A 241 should hold up to a 1st gen with no problem. I agree a 205 is strong but for the money I can buy alot of 241s.

 

I've got a 241C behind the Duramax/Allison in my truck and it is taking it fine so far at around 420hp at the crank, even with a trailer, so from a power stand point you should be safe. I used the 29 spline input gear from the 261XHD that came behind the Allison in the 241C though just because I already had it, but it required welding up the stub shaft between my cases (241/241 doubler) because the input gear in for the 261XHD has a larger bearing than the 241C. I would just about bet that the 29 spline input from the DLD/DHD would be a direct swap in a C though. If this is a slow project I may be able to let you know because I have to swap the input gears between the Dodge cases to go from a manual to automatic for a customer at some point in the near future.

 

ok that would work. im not sure when i will get to putting this transfer case togather. i can get new dodge input shafts for around 90. and 241C's for around 100. so this would sav considerable money compared to a 205 for a cummins.