NP205 T-Case found!

[86m1028]

I think you are missing the intermediate shaft. I believe there is a short section of shaft that fits in the spacer. the bolt on the side rides in a groove on that shaft keeping it in place.

The 205 I rebuilt for my truck had a short shaft In that spacer. I do not know what my 205 came off of but it was a figure 8 small bearing 27 spline shaft.

Maybe it is not needed with the TH400 and mine came off of something else.

No intermediate shaft or coupler on the 400/205.
The 205 uses a female shaft to male 400 shaft.

You will probably need the "long" input shaft for the 205 to bolt it up to your stock turbo 400.

 

[MAZ537]

After some search I found that NP205s up to 84 use the short input gear (mine has 84 date stamps as well) , 85 and up use the long input gear and this is what I need to be able to use it...

Is that correct or no ?

Thank you,
G.

 

[rustystud]

After some search I found that NP205s up to 84 use the short input gear (mine has 84 date stamps as well) , 85 and up use the long input gear and this is what I need to be able to use it...

Is that correct or no ?

Thank you,
G.

That's correct to a point. All TH400's use the short shaft on the figure 8 NP205 . There is no intermediate shaft in a NP205. It is the input gear itself which mates up to the transmission output shaft.

 

[cucvrus]

I am confused. If you bought the entire transmission transfer case assembly it will fit regardless? Our am I missing something?? Why has it become so controversial about what fits what? It came from a CUCV or a chevrolet. From my observation of the crossmember it was cut from a CUCV. Correct? Or what am I missing? Just have the transmission rebuilt and reseal / look over the transfer case and bolt it up.

 

[MAZ537]

I bought just the transfer case with the adapter , not the transmission.
It is not cut from a CUCV as it has an gas V8 engine attached to the transmission...

Thank you,
G.

 

[cucvrus]

That is why i had previously said to buy the entire assembly if it were available. The torque converter would be the only difference in the set. That is OK I hope things work out for you. I think they should. I know the CUCV had the same cross member as the 77-84 1 ton trucks if I remember correctly. Good Luck. Thank you for sharing.

 

[86m1028]

After some search I found that NP205s up to 84 use the short input gear (mine has 84 date stamps as well) , 85 and up use the long input gear and this is what I need to be able to use it...

Is that correct or no ?

Thank you,
G.

Since you are keeping your original trans (400), you will need to swap to a long 205 input in the 205.
I would suggest rebuilding the tcase while you have it out & are replacing the input gear.

 

[86m1028]

That's correct to a point. All TH400's use the short shaft on the figure 8 NP205 . There is no intermediate shaft in a NP205. It is the input gear itself which mates up to the transmission output shaft.

Except the Cucv's, they used the figure 8 adapter with the "long" input.
All of the M1031's & M1028A1's used the long 205 input with the figure 8 adapter.

 

[cucvrus]

I pulled a 400 TH transmission and 205 transfer case from a 1986 Chevrolet Cab Chassis K30 and it was a direct fit. I did use the cross member from the cab chassis it was different because it was a 1986. I was unaware of all the variations so I just kept the pair mated together and had both overhauled and resealed before I put them in an M1028. I still have a 205 spacer from a CUCV. And I have an early 205 from a stick shift K30.

 

[rustystud]

View attachment Scan0048.pdf

Except the Cucv's, they used the figure 8 adapter with the "long" input.
All of the M1031's & M1028A1's used the long 205 input with the figure 8 adapter.

OK, I haven't looked at my manuals yet so I might just be stepping in the pooh here but I believe the only NP205's that used the long shaft in the 1980's where behind the SM465 4 speed manual transmission.
There is no difference between Military and Civilian drivetrains in these trucks. The major difference is of course the 24 volt system. There are "small" differences but nothing major like transmissions and transfer-cases and differentials.
There is only four TH400 output shafts that are used for any 4X4 application. There is only one for the NP205. It can come threaded for a yoke or not threaded.
Also the M1028A2 &A3 and M1031 trucks where the only ones to use the NP205 transfer-case and they came with the rear slip yoke ( though the "synchro" model was also being used like mine had). All other CUCV's used the NP208 transfer-case.
My truck is the M1028A2 with dual rear wheels. I removed the NP205 synchro unit and rebuilt it with a 32 front and rear spline fixed yoke output shafts.

 

[MAZ537]

Now to the search for a long 32 spline female input gear...Any leads for one guys ?

Thank you,
G.

 

[rustystud]

View attachment Scan0110.pdf

Except the Cucv's, they used the figure 8 adapter with the "long" input.
All of the M1031's & M1028A1's used the long 205 input with the figure 8 adapter.

As usual there are many answers to the same problem. Your partially right about the NP205 input gears. The longer style was used in the later model 6 bolt style NP205. The shorter is the one used in the figure 8 pattern NP205 like I said earlier.

 

[cucvrus]

Now to the search for a long 32 spline female input gear...Any leads for one guys ?

Thank you,
G.

Can't you just get the transmission that the transfer case was bolted to? That would have all the parts you are in search of.

 

[richingalveston]

http://offroaddesign.com/catalog/NP205 Parts.htm

check here: I have the fat shaft with Magnum box on a 4l80e, but they probably have what you need along with all the gaskets to rebuild in a one stop shop

Their stuff is good. I have a lot of it on my truck.

rich

 

[86m1028]

View attachment 620629

As usual there are many answers to the same problem. Your partially right about the NP205 input gears. The longer style was used in the later model 6 bolt style NP205. The shorter is the one used in the figure 8 pattern NP205 like I said earlier.

And there are always exceptions.
The Cucv's with 205's use the "long input" with the older fig 8 pattern adapter.
I have 3 of these trucks (with factory 205's), all have figure 8 adapters with LONG inputs.

 

[rustystud]

Can't you just get the transmission that the transfer case was bolted to? That would have all the parts you are in search of.

That's what I was wondering about too ! Why just buy the transfer-case and leave the perfectly good TH400 behind ?

 

[rustystud]

And there are always exceptions.
The Cucv's with 205's use the "long input" with the older fig 8 pattern adapter.
I have 3 of these trucks (with factory 205's), all have figure 8 adapters with LONG inputs.

Now that is truly interesting ! I wonder why they did that ? In the Circular 6 bolt pattern NP205's the adapter housing is just a bit longer then the figure 8 pattern housing, so they needed the longer shaft. I have an original 6 bolt pattern housing on the shelf downstairs right now. I bought it when my friend at the GMC dealership parts department told me that GM was obsoleting the part.

 

[Recovry4x4]

This thread has been truely helpful. Alot of this info I had hear before but while trying to confirm the data, I stumbled across info that will allow me to retain a 32 spline 465 and use my figure 8 adapter and NP205.

 

[rustystud]

This thread has been truely helpful. Alot of this info I had hear before but while trying to confirm the data, I stumbled across info that will allow me to retain a 32 spline 465 and use my figure 8 adapter and NP205.

Now that is a rare beast. A SM465 with a 32 spline output shaft. Most all 4X4's that used the SM465 had a 10 spline output shaft that went into the NP205 transfer-case.

 

[MAZ537]

The TH400 is not for sale guys...
I clean it up and also have the oil drained , clean and free of any shavings , also has good smell...
After some more search I found that my 205 is a more rare ; synchronized unit ?