does anyone know if there is any difference in the transfercase on nthe 05's with the active center diff. and the 03 04's
thanks

 

Of course there is a difference. The ACD. It has the associated pumps, plumbing, and its own computer to determine how it operates. The ACD causes the TC to be slightly larger than the 03-04....people had a hard time finding a DP to fit the 05 when they first came out. There were rubbing/rattling issues.

If you want to know specifics of how the ACD works I suggest doing a search on it.

 

If you threw an '05 TC on an '03 and hogged out all of the various ACD components, could you gain some more volume for fluid?