Transfer Case Decisions - Gear vs. Chain Drive - 4-Wheel & Off-Road

Harry Wagner Contributor

In the early days of 4x4s, transfer cases like the Spicer 18, Dana 300, and NP205 were the norm. These cases all feature iron cases and are gear-driven for incredibly strength, but as manufacturers searched for ways to make 4x4s quieter and more fuel efficient the NP231, NP241, and NP271 emerged. By contrast, these transfer cases use aluminum cases and are chain-driven with planetary gears of varying size (depending on the application).

Gear Drive Vs Chain Drive Transfer Case Decisions Dodge Ram Driving Through Mud Photo 48097513
These two transfer cases have been the cornerstone of ¾- and 1-ton truck applications for decades

We went to National Fleet Solutions where an NP205 and an NP271 transfer case spilled their guts for us at the hand of shop manager Aaron Lechner. These two transfer cases have been the cornerstone of 3⁄4- and 1-ton truck applications for decades, and both designs have their advantages and disadvantages depending on your budget, space requirements, and how you primarily use your 4x4. Read on to help determine which one is right for you.

Gear Drive Vs Chain Drive Transfer Case Decisions Group Of Gears Photo 53081880

NP271 or NP273, What’s the Diff? The NP271 that we used for this story uses a manual, floor-mounted shift lever, while the NP273 is essentially the same transfer case with an electric shift motor. The NP273 also adds a synchro ring for shift-on-the-fly capabilities. Otherwise the cases and internals for both transfer cases are identical, and components can easily be swapped between the two cases.

PhotosView Slideshow When viewed next to each other, it is easy to see how much larger the aluminum, chain-driven NP271 case (top) is compared to the cast iron, gear-driven NP205 transfer case. The main shaft on the NP271 (right) is notably larger than the NP205. The largest NP205 measures 13⁄8 inches, while the NP271 is 13⁄4 inches, both measured at the rear output. The NP205 (left) uses a combination of gears for a low-range reduction of 1.96:1, while the NP271 uses a planetary for 2.72:1 reduction. The tradeoff is that planetary gears run quieter and cooler, but the unit has more moving parts. There are very few moving parts in an NP205, and they are all steel. A variety of male and female input shafts were available with different spline counts depending on what transmission was used. The NP205 uses a one-piece case with the gears added through the rear, which is more rigid than the clamshell, two-piece design of the NP271. There are also fewer fasteners and moving parts in the 205. The 10-spline input on the left was most commonly used with the SM465 transmission, while the 27-spline input gear on the right is from a TH350 automatic. These are both direct-mount inputs, but divorced-mount NP205s were also used in some applications. If the CV joint on the front driveline seizes up on an NP271-equipped truck it is not uncommon for the whole case to come apart as a result. The large aluminum housings don’t like impacts either, so build a stout skidplate for protection in the rocks. Ford used a fixed rear output (left) on the NP271 from ’99-’07 before switching to a slip yoke (right). Dodge never used a fixed yoke in a factory application, but the Ford parts can be retrofit with factory parts. The NP271 requires a gear oil pump to lubricate the planetary assembly and pilot bearing. These transfer cases run ATF, so if you have an automatic you can carry less spare fluid on the trail. One of the unique features on the NP271 is that the chain-drive gears are identical for the front and rear. They are splined and retained on the output shafts with snap rings, simplifying repair and parts swapping. The chain used on the NP271 is quite robust and not as prone to stretching and rubbing the case as the smaller NP231. The 271 has a torque rating of 7,890 lb-ft, while the 231 has a torque rating of only 1,400 lb-ft. Offroad Design offers adapters to mate the gear reduction half of an NP203 transfer case in front of the NP205 for Ford, Dodge, and Chevy applications like the TH400 transmission shown here. Gear Drive Vs Chain Drive Transfer Case Decisions Transfer Case Comparison Chart Photo 48097537