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700R4 to 203

RGV72BLAZER

RGV72BLAZER

1/2 ton status
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Well getting ready to build the x-members for my doubler/tranny; however, I'm still unsure of the output shaft on the 700R4. I bought a 2" spacer from 4x4High several months ago to mate the tranny to a 203 using the 203 adaptor; the tranny was already built so no sense in tearing it down to replace the output shaft with the AA short shaft. But now I can't decide if I need to trim a bit off the output shaft or if there's enough connection between the female end of the 203 and the 700R4's output shaft. I took some measurements today, just wanted to hear some suggestions, opinions, etc, and I took the measurements by laying a straight edge down...

Here's the whole combo, 700R4-2"spacer-203 adaptor-203 flipped-NWF doubler-LoMax:
IMG_3459.jpg



Here's the bare output shaft with no adaptors, measurement reads 1 13/16":
IMG_3464-1.jpg



Output shaft with 2" spacer, measurement reads 1/16":
IMG_3463-1.jpg



End of output shaft to end of 203 adaptor, measurement reads 15/16":
IMG_3467-1.jpg



203 retainer, reads 2":
IMG_3468-1.jpg



So judging by the 203 length & the mating surfaces between the 203 adaptor and 203, it seems there may be about 1" of connection between the output shaft and the 203 female end. I hope this all makes sense, but I'm just wanting to make sure everything is a proper length. So any ideas whether I need to trim some, remove the 2" spacer, or looks good as is? Thanks in advance.
 
As long as the output shaft of the tranny doesn't bottom out in the 203 input gear you're good. If it does bottom out then you'll need to trim a slight amount off the 700 output shaft. I did have that whole assembly together on my bench with that adapter and it was fine with my 700R4. When i get home tonight i can meaure the stick out length of the 700R4 that i had it mocked up to.
 
I keep looking at the stick out length on your 700R4 and it seems pretty short. Are you sure it's not a short shaft in there?
 
Last edited:
I just remembered to measure the stick out on my 700R4 that i used for mock up. The stick out is 3" from the end of the case to the end of output shaft. There is a bevel on the end of the shaft before you get to the splines. From the end of the shaft to the beginning of the splines is .220". The spline length is 2.375". So someone has either cut roughly 1" off the shaft in your tranny or there's something else going on with it.
 
The bevel is just to facilitate ease of mating up the splined shafts.
 
You need to figure out why your output shaft is shorter than it should be. My trans had a NP241 behind it and the shaft is the original shaft so i know the length is correct for the application. Your shaft beins only 1 13/16" is an inch shorter than it should be which won't allow you to use the spacer and have proper engagement of the splines.
 
that is weird hmm. i might need that spacer if its not gona work for you:).
 
700 r4 to 203

Ok, reading from your post makes sense but i want to ask to make sure before i get into build. I have a 700 r4 i want to put in my 77 k5 that allready has a 203 full time transfer case in it. The trans is allready apart for rebuild so my question is, can i run this setup by changing the output shaft in trans or do i need that spacer. Reason im confused is bout 10 years ago i had a 700r4 in an 84 blazer and it was going out, so i put a th350 i had in it and only had to use a 2" spacer in between. ??:dunno:
 
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