The black jeep - 1 ton XJ

any plans to upgrade to 6 pinion, and how do you plan on pressing in the sun gear?
 
I'm gonna grab a 6 gear from the JY. Install annulus with my little 12t HF press.
 
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I decided I’m just gonna use my 3 gear since I already have it. But I’m probably still 12 weeks from getting my box.

Post some assembly pics and any tips or tricks. Can’t wait to build mine.
 
Wife just sent me this. Finally here.

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Eco box install.
Kball your oem tcase input, plastic washers x2, retaining washer and c clip. Install them into the 6 gear planetary.
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Install order is as follows. Be sure to clean all parts with lint free cloth and apply some gear oil on all parts.

Plastic washer
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input gear
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Plastic washer
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Metal washer
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C clip
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Press the annulus gear into the forward case half. The recess goes down into the case first. Make sure the gear is flush with the case.
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Eco ford NP205 specific install.

Install the NWF gear then the provided c clip into the NWF output shaft.

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Install the NWF gear/shaft into the case by removing the rear output assembly. Put the shift ring back into the shift collar. Laying the case flat made this much easier.
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Install the oem rear output shaft/gear assembly into the NWF shaft. Be mindful of the roller bearings and make sure they don't fall out. Apply plenty of grease to keep them in place.
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Install the rear output assembly.
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Back around the front, install the oem NP205 bearing and bearing c clip. Install the NWF provided c clip into the shaft.
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Install the your kballed shift collar/ gear into the NWF shift fork.
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Install the aft case half onto the NP205 with the NWF provided long bolts and nord-lock washers. This case half is not clockable and can only be installed one way. Apply some RTV between the np205 and the NWF case.

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Install your planitary gear/ input shaft assembly.
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Install the forward case half with the NWF provided short bolts. Apply RTV between the NWF case halfs. Install your kballed(np231) bearing, bearing c clip into the front NWF case. Install the kballed (np231) c clip into the input shaft. Apply RTV on your kballed input gear seal retainer and install it onto the front of the NWF eco box. I reused the oem panhead bolts and did not use the NWF provided Allen head screws as they seal better.
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Clocking the NWF doubler to the jeep trans (aw4 or ax15) is done as follows.

There is a w machined into the front of the doubler to ID the wide mounting holes on the trans.
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These 2 studs index into the trans at the 9 and 11 o clock positions.
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If anyone is curious this setup is exactly 19". I believe the titan black box is 3/4" shorter because the NWF input gear and shaft is a machined 1 piece unit and a little shorter than the 2 piece eco version I bought.

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What’s the weight? The ‘official part weight’ thread might benefit from knowing.


Awesome detailed install.
 
Fuck yeah thanks for going into that detail for the assembly. Can’t wait to get mine.

I think I asked you this before but forget, why 205 this time instead of 300 again like the Comanche?
 
fl0w3n said:
Fuck yeah thanks for going into that detail for the assembly. Can’t wait to get mine.

I think I asked you this before but forget, why 205 this time instead of 300 again like the Comanche?
Click to expand...

The d300 is really junk in comparison. You have to upgrade the front/rear outputs to 32 spline and it’s still not as strong as a bone stock np205. I paid $300 for my np205. I paid $500 for my d300. Both outputs, gears, shifters and the d300 equals $3060. Also the d300 flipped sucks as it leaks from every single possible place. Shifters also suck and require custom cables which ad the cost up even more and are junk/ sloppy compared to direct link shifters. Hindsight is always 20/20. If I knew what I know now I would have a 205 under the MJ.
 
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For $3,060 I’d just round up and buy an Atlas and still need custom cables. You just made one more reason it’s a logical step from a 231.
 
Mike Honcho said:
The d300 is really junk in comparison. You have to upgrade the front/rear outputs to 32 spline and it’s still not as strong as a bone stock np205. I paid $300 for my np205. I paid $500 for my d300. Both outputs, gears, shifters and the d300 equals $3060. Also the d300 flipped sucks as it leaks from every single possible place. Shifters also suck and require customs cable which ad the cost up even more and are junk compared to direct link shifters. Hindsight is always 20/20. If I knew what I know now I would have a 205 under the MJ.
Click to expand...
All solid points, except are you including a JB gear set in the $3060 and comparing to stock geared 205?

If I hadn’t gotten a steal on my 300 I’d probably be considering something else in the XJ.

I’m dreaming of the next future build already and I’m considering going Magnum + 205. I may be picking one up for free in April depending if the guy still has the setup.
 
Have you decided on a shifter setup yet or have any idea how you're going to mount shifters?
 
well that isn't cool. I was just going to buy what you did and hope it works with a different transfer case.
 
To install a large t case in an XJ you have to completely cut out the floor/center console. That is unless you want the t case hanging down like a boat anchor:lmao:

My fancy $400 cable shifters suck. You can make a nice set of direct link shifters with a few parts from Ace and some scrap metal and for cheap !
 
The shift rods and linkage isn't what I'm racking my brain about, it's the pivot points - for me at the 300 rails and below the actual shift lever is what I'm having a hard time wrapping my head around.

Like runningproblem, I'll look to you for ideas while I wait for my stuff to show up :grinpimp:
 
Yeah the pivot points are what is confusing me mostly. Also, my general lack of fabrication skills.
 
Cut some more sheet metal and test fit the t case. Fuck this thing is heavy:lmao:

Happy with how it's clocked. Going to trim a little more for the front driveshaft and then start boxing it box in.
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I think we all want to weld like that :lmao:, I just have a $90 harbor freight flux core to get me by on a budget and without 220 in the rental garage. What machine are you using? If all goes well this year we’ll be buying a place and I can finally get 220 in the garage and pickup a big boy welder.
 
It's pretty easy to install a 220 circuit breaker or if the laundry room is close just make a 50amp extension cord and unplug the dryer.

I have a miller 215, nice machine and does everything minus AC tig. I would probably buy the miller 220 if I was in the market today.
 
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