Advance Adapters 50-0220 - Manual

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific type of conversions. Modifications to any of the components
will void any possible warranty or return privileges. If you do not fully understand modifications or changes that will be required to complete your conversion, we strongly
recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter components. We
recommend that a service manual pertaining to your vehicle be obtained for specific torque values, wiring diagrams and other related equipment. These manuals are normally
available at automotive dealerships and parts stores.
KIT CONSISTS OF:
No. Qty Part No. Description
ADVANCE ADAPTERS INC. P/N: 50-0220
P.O. Box 247, 4320 Aerotech Center Way Kit Revised: (11/96)
Paso Robles, CA 93447 PAGE 1 OF 4
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 03-13-14
Optional Item
1. 1 51-0220 ADAPTER RING FOR FORD T/C
2. 1 52-0220 SPUD SHAFT WITH 31 SPLINE x 29T INTERNAL
3. 2 716517 GASKET - NP208 T/C
4. 6 723704 LOCK WASHER 3/8" PLATED
5. 6 723724 H.H.C.C. 3/8"-16 x 1-3/4"
6. 6 723735 3/8" FLAT WASHER PLATED
7. 6 723766 S.H.C.S. 3/8"-16 x 2" PLT. GD. 2
8. 1 NV001 NV INSTRUCTION MANUAL (only available online at www.advanceadapters.com)
The Borg Warner transfer case will need 10 MM x 1.5 thread SHCS bolts. The heads are turned to fit the adapter casting
and are stocked under our part number 716470 (6 needed). We do not ship these in the kit unless specified. If you have
already received this kit and need the modified bolts for the B/W transfer case, please call and we can ship them no charge
to you in the continental U.S.
DODGE 4WD 29T NV4500 5 SPEED TO
FORD NP205/208 & B/W T/C's
SPECIAL INSTRUCTIONS:
When assembling the transmission to the transfer case, DO NOT FORCE the two gear boxes together. If the shaft is
too long, there is the possibility of pre-loading the transmission bearings for premature failure. Take the extra time to
make sure that the shafts do not bottom out internally. If there is an interference problem, it may be necessary to grind
the end of the new output shaft to obtain the proper length. The seal in the stock Dodge tailhousing needs to be removed
to allow the spud shaft to fit properly onto the Dodge output shaft.
All Ford transfer cases whether NP205 or NP208, always require a 31 spline male input shaft. We have seen some
variations as to the stickout length of this 31 spline output shaft. Before assembling the new transmission to your transfer
case, you should compare the stickout length to the original transmission and make the necessary adjustments.
Before assembly of transfer case to transmission, the transmission tailhousing will have to be pocketed for clearance of
the transfer case shift rails and cross link.
1. Align U-shaped notch of adapter with rearmost cylindrical boss of tailhousing, keeping in mind that the tailhousing's
bolt pattern aligns with adapter's tapped hole bolt pattern. Once aligned, transfer outline of notch to tailhousing with
felt tip marker.
2. Take a 1/4" drill bit and wrap a piece of tape around bit 7/16" from the tip. This serves as a depth gauge. With a hand
drill or drill press, drill as many holes in the outlined area as possible.
3. With a cold chisel, knock out the remaining material. With the shift rods in the fully extended position, make a trial
fit of components to ensure that the pocket depth is enough to clear shift rods and cross link.
715528 NP205 Transfer case
shifter brkt.
Note: The stock oil seal in the NV4500 tailhousing must be removed.