Transfer cases! SOS!!

[Redcap]

Originally Posted by willett

I should have mentioned that my 203 is part time and I have locking hubs already. Part of my original concern about the case is that the 203 diff is shimmed rather than replaced by the $400 milemaker shaft setup. I recon there is one of those in my near future as there is quite a bit of play in my case currently
Posted via Mobile Device

I wouldn't waste the money putting a 203 back in, but I suppose that depends on how much and how hard you use 4WD.

[76k10]

I have been following this thread very closely.

One concern I have had is where can you get these shaft replacement kits? They appear to no longer be made.

Also, lately I have read more and more 203 success stories rather than failures. I supposed proper lubrication and care goes a LONG way with these cases.

[willett]

It looks like I have 1 more option: The friend thy I ended up 'giving' the previously mentioned 205 to says he has an sm465 205 that I can have. I have always been very interested in divorcing my 203 and mating it to a 205. This will solve my input shaft issues but I realize the cost of the kit is quite high. Perhaps I can fabricate a mounting bracket. If I can do this I only have to worry about driveshafts and fabricating shifters. Hmmmm
Posted via Mobile Device

[76k10]

Originally Posted by willett

It looks like I have 1 more option: The friend thy I ended up 'giving' the previously mentioned 205 to says he has an sm465 205 that I can have. I have always been very interested in divorcing my 203 and mating it to a 205. This will solve my input shaft issues but I realize the cost of the kit is quite high. Perhaps I can fabricate a mounting bracket. If I can do this I only have to worry about driveshafts and fabricating shifters. Hmmmm
Posted via Mobile Device

Does this mean you are going to build a doubler? Nice idea.

[Redcap]

Originally Posted by willett

It looks like I have 1 more option: The friend thy I ended up 'giving' the previously mentioned 205 to says he has an sm465 205 that I can have. I have always been very interested in divorcing my 203 and mating it to a 205. This will solve my input shaft issues but I realize the cost of the kit is quite high. Perhaps I can fabricate a mounting bracket. If I can do this I only have to worry about driveshafts and fabricating shifters. Hmmmm
Posted via Mobile Device

http://offroaddesign.com/catalog/doubler.htm

[willett]

How many splines in an sm465 205 input??
Posted via Mobile Device

[kwmech]

Originally Posted by willett

How many splines in an sm465 205 input??
Posted via Mobile Device

Early figure 8 pattern is 10, late model circle 6 is 32

[Redcap]

Originally Posted by kwmech

Early figure 8 pattern is 10, late model circle 6 is 32

Yup.

[willett]

I have to take a look at this free t case and make my move from there.

ORD doesn't offer a doubler kit for anything other than a 32 spline 205 because they say everything else is comprisable. Apparently the 10 spline shafts can develop quite a bit of slop. I did see another outfit (northwest fab I think) that makes a 10spline kit for around $600.

Do any of you guys have any say on the resilience of 10 spline?

Im going to have to sit down and do the numbers, but I think I'd be in the $400-$600 neighbourhood rebuilding my 203 anyways, And
a)I don't really want to have to upgrade down the road (I know I'll want to), and
B)how awsome would it be to have 3 sticks on the floor (of course I'm going to twin stick the 205!!
I'll let you guys know later. (I'm at work right now). I think that aside from cost of the doubler kit, my only other concern is going to be finding a long enough front driveshaft to cut down v
Posted via Mobile Device

[willett]

http://www.northwestfab.com/GM203GM2...g-8_p_905.html


Correction, $700
Posted via Mobile Device

[csb#356]

You gave away a th400/205? I would attempt to get that back. They aren't the easiest thing to find. Taking apart the transmission and puting it back together is not hard. And a seal kit can be had for 40 bucks. You wouldn't have to take apart any clutches or the pump. Just take off some snaprings and pull stuff out, then stack it all back in. Don't be afraid of automatics, they're not as mysterious as everyone makes them sound.

[willett]

its okay, my buddy needed the setup more than I do, plus as I said he is giving me a 205 off of an SM465 and I'm getting pretty excited about running a doubler.

[Rubble]

Originally Posted by csb#356

You gave away a th400/205? I would attempt to get that back. They aren't the easiest thing to find. Taking apart the transmission and puting it back together is not hard. And a seal kit can be had for 40 bucks. You wouldn't have to take apart any clutches or the pump. Just take off some snaprings and pull stuff out, then stack it all back in. Don't be afraid of automatics, they're not as mysterious as everyone makes them sound.

I didn't think the 400/205 combo was that rare,I got one in my 81crew and 2 more out of parts trucks,a 1980 K20 & 1986 K35 I just parted out.Maybe depends on what part of the country your in and I didn't really hunt these down cause of the combo either,just fit in my collection...
Posted via Mobile Device

[csb#356]

Originally Posted by Rubble

I didn't think the 400/205 combo was that rare,I got one in my 81crew and 2 more out of parts trucks,a 1980 K20 & 1986 K35 I just parted out.Maybe depends on what part of the country your in and I didn't really hunt these down cause of the combo either,just fit in my collection...
Posted via Mobile Device

They are a pretty tough find here for a decent price. I wouldn't say they are rare but let me put it this way. You can walk into a salvage yard any day of the week and find a sm465/205 combo. I usually find them pulled already and they only want 60 bucks for the transfer case. I have never seen a 32 spline 205 in a salvage yard ever. They show up on craigslist from time to time but they don't give'm away. People that have them, keep them. I didn't mean any disrespect, I'm all for helping out a friend.

Also are you sure the one in the K20 wasn't a th350/205, that setup wasn't available in a 3/4 ton.

[Rubble]

Originally Posted by csb#356

They are a pretty tough find here for a decent price. I wouldn't say they are rare but let me put it this way. You can walk into a salvage yard any day of the week and find a sm465/205 combo. I usually find them pulled already and they only want 60 bucks for the transfer case. I have never seen a 32 spline 205 in a salvage yard ever. They show up on craigslist from time to time but they don't give'm away. People that have them, keep them. I didn't mean any disrespect, I'm all for helping out a friend.

Also are you sure the one in the K20 wasn't a th350/205, that setup wasn't available in a 3/4 ton.

Yup,turbo 400 behind a 400 SB. It was that way when I got it,maybe someone did some swapping before....
Posted via Mobile Device

[willett]

I just found out the free 205 is actually from a th350. This is better!

The only problem is that it has a slip yoke rear output. Is there any minscule chance that the yoke from my 203 is compatible?
Posted via Mobile Device