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Discussion Starter #781
I'm somewhat confused about mounting a late NP205 transfer case to an Allison. In what situation will a 205 bolt up to an Allison without the need for a spacer? Would installing a 29 spline female input or if the 205 already had a female 205 input be sufficient to mate the transfer case and Allison without using a spacer? Female 29 Spline NP205 Input Gear
If you use that ORD input gear, then you can indeed bolt a round pattern 205 directly to a round pattern 4WD Allison tailhousing. You will have to cut out a semi-circle in the t-case mounting face on the trans for the rear shift rail if you go that route. Make sure you have front driveshaft clearance by doing a mock fit-up. This means removing the front shift shaft, which is it's own PITA, but you don't want to notch out your tailhousing for the shifter shaft only to find that you have to clock the t-case up or push it back, both of which involve spacers anyway.

Max, does this look right?

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You got the basics down fine. As far as EFI Live "version", you will need the latest software for the Flashscan. If you are asking which Flashscan, it's going to be the Flashscan V2.


Thanks for all the fantastic info MaxPF. So if I pick up a late model trans and Tcase from a Dmax can I just run my existing 5 speed TCM to get me going? Using my SAE bell and sensor.
Any years of Dmax?
This keeps my wiring stock and if i want to upgrade to the 6 speed in the future its just TCM/wiring change. Buying a 4X4 housing, output shaft and differant Tcase is almost the same cost as a used Dmax setup.
My console shifter just has PRND, there is no reason to have the 1st position from an operational standpoint?
No. The valve bodies in the 5 and 6 speeds use different solenoids with different electrical characteristics. You cannot use a 5 speed TCM on a 6 speed VB or vice-versa. You CAN swap the 5 speed parts (valve body, shifter shaft, internal wiring harness, and external NSBU/mode switch) into a 6 speed, and that WILL allow you to use the 5 speed TCM. Just make sure you keep all the 6 speed parts nice and clean, put away in ziploc baggies or whatever, as you will have to swap them all back in to run a 6 speed TCM.
 

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Guys, please help! I have been stalking this discussion for two years now. After putting the final touches on my 2002 Ram,5.9 cummings 3500 2wd Allison swap, And removing the bad NV5600, I turned the key and my 13 tooth factory starter drive is hitting the flix plate front with zero engagement, after being on the phone all day with napa we came to the conclusion, that I needed the ten tooth drive. Now for the info, you need to know on my swap. I took the cheap commercial route. My donor trans is out of a low mile 2009 Silverado 2500. my flix plate number is 3918959. what starter do I need? I know I posted this in the wrong way.. and if so give me a hard time but please help, I need this truck running in the worst way!
 

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Discussion Starter #783
Do you have the part number for the SAE #3 housing? Or, do you know what the original application that housing came out of? Either of those will be needed to definitively determine which starter part # is the correct one.
 
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I'm not sure what the donor vehicle the swap kit came out of. I would think a med duty app of some sort that had the 5.9 Cummins and Allison. I picked it up on eBay for 199.00. no one bid was told it would keep the starter on the same side, so no rewiring needed. here's a photo of the parts I used in the swap. I do have the flexplate ID number 3918959
129075
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Max, I have a few folks helping me work on this issue. one person told me the starters that were used in the first-gen 5.9 were offset a bit different but were also 13 teeth. here's a photo of the flexplate when I pulled the starter.
129076
 

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Max, this is what I have . it seems that I have seen in your tread where someone did this exact same swap set up. i remember the keeping the starter on the D/S was the big deal. This is driving me crazy!
 

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Discussion Starter #787
The listing shows what P/N flywheel housing you have: 3925223. I believe the starter you need is a 6573.
 

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This thread is going strong for over 10 years - THANKS to MaxPF for maintaining it.

Russ
 
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Is a 2006 chevy c5500 8.1 tcm the same as a 2006 chevy 2500 8.1 tcm looking for a tcm whit tps for a 06 ALLISON 6spd for a swap in a ford f350
 
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