Fixing Detents on newer 205 tc

[Scrub]

I have an 87 k30 with the newer style 205 t-case. The Detents are broken as it will pop out of gear unless you bungie the shifter into 4-HI and roll the hubs out.
The older 205's had big cap bolts on top of the case that you popped off and replaced the springs and balls. This case has only rubber plugs in small holes that don't appear (in a mirror with a flashlight) to have anything in them. There is a large sensor that looks like it might have an intigral spring and button, but that is only on the 4wd rail. I believe my problem is in the Hi-Lo rail.

Any help would be appreciated.

[Scrub]

I answered my own question.
The 4x4 rail detent is under the switch and the HI-Low detent is buryed under grease and dirt where it should be.

No springs broken, still popping out of gear. I guess I need a new t-case.

[1969 GMC]

If you do need a new t-case, good luck. I am trying to find a 32 spline 465/205 combo locally and they are just plain hard to find (I want to convert to 32 spline to get rid of the coupler sleeve and add some strength).

If you do have to buy an older 10 spline case, you need to get a new input gear and bore the case where the input bearing goes, as its larger on the 32 spl. Good luck

[72addict]

If you dont need the 4x4 indicator light you can replace your shift rails with old style shift rails that have deeper detents. I put a 205 in my 1998 k2500 and I had to weld up the shift rail and machine it to match the new style with the indicator light. I needed the switch to engage my front diff.

[Scrub]

Thanks.

I found a rebuilt for 800 bucks exchange... That answers that question.

I am thinking about adding some spacers to tighten the spring and a new detent ball as the one in there was a little banged up. After that, I might just put a solid block in there to lock it in high range until winter and more time to fool with it.

I am thinking of rebuilding it myself as I have all the instructions and the kit is $163.00.

Adam,
This one has the single circle front bolt pattern instead of the old double-bubble bolt pattern, so boring an old case wouldn't work anyway.


72Addict,
I have an older parts case. I pulled the detent balls and springs and they look identical to the newer ones. I can't see into the holes on the newer case to tell, but you say the rails on the older one are deeper? If so, I guess I should use the older rails when I rebuild.

Any other suggesions. It has the 27 spline front output, which is fine on this rig.

Thanks again,

TW Scannell

[1969 GMC]

I guess I forgot about the different mounting patterns, although I do believe you can "redrill" the case to accept the round pattern, but that just sounds scary. I think some of the guys running 203/205 doublers over at pirate4x4 did this. still, it would be too much hassle.

I guess I forgot to mention that ORD sells an adapter that allows you to use a stock 10 spline 465/205 adapter with the long 32 spl output, provided you have a 205 that can accept 32 spl. that is the way I am thinking of going, it seems kinda convoluted but its the only way to go unless I find a complete newer setup. I guess I got your problem and mine confused.... sorry about that.

[Scrub]

Here's your new t-case

http://cgi.ebay.com/ebaymotors/ws/eB...category=33727

I think this is the older style t-400 case with a short 32 spline input. Price is right.

Good luck

[1969 GMC]

thanks, but I think that is for a TH350, 27 spline. the reason I say is, the front input is male, and would require a coupler sleeve to adapt to the transmission. TH400 NP205's have female 32 spline inputs with no coupler sleeve. still a good price for someone that needs one...thanks again!

[72addict]

the deeper detents are in the shiftrail that was superceded by the rail with the switch/detent ball. The old style rail that did not use the switch has deeper detents.