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Blue Truck

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Things are about to get hot and heavy on this project. I got a "Floor Shift" tilt column ordered, flywheel and clutch, JB twin stick cable shifter. I figure I'll install the steering column next, then do a little rewire where the harness previously connected to the neutral safety and reverse switch on the original AT column. After that, pull of the trans hump cover and cut a few holes in it. In the meantime here's a few pictures of my new headliner.

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Spent a good part of the day last Friday swapping out the shift rails for twin stick rails and hooking up the shifter, sure is a fun toy. Saturday was mostly hurricane prep and I haven't touched the truck since. House did OK, but we don't have power. Now I am stuck at the refinery helping sort out the mess left by the hurricane.
 
Had a pretty hard time finding a spot to mount the t-case shifter, finally did some cutting and made my own bracket to bolt it to the side of the transmission.

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Filled everything up with gear oil, did my best to adjust the clutch, ran through my checklist again and cranked it up. Took it out for a test drive and everything it seems to work. My speedometer and odometer do not work, so I guess the original 1976 cable is not compatible with the "new" NP205. My best guess is that the 205 is 1985 or newer, and it has a 1350 rear output yoke. Any tips on what to do with the speedometer/cable?

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Well, it looks like the drive gear inside the "new" junkyard NP205 is worn out or stripped. I took out the sleeve and the gear (1 & 5) on both my old 203 and the "new" 205, and felt the gear inside the t-case that would drive No. 1 on the picture below. The teeth in 205 gear kinda feel a little less-than the teeth in the 203, so I'm guessing they just aren't driving the speedo gear. I put it all back together, then stuck a twig into the end of the driven gear where it connects to the speedo cable. When I rotate the rear output with my hand, the (old) 203 would visibly turn the twig but the (new) 205 (in the truck now) does not. Looks like I need to change this gear. Anybody know how to do that? Also, would the 203 gear be interchangeable with the 205 gear?
Thanks,
Ben

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I was able to confirm that the plastic internal speedometer drive gear is interchangeable between an NP203 and NP205. Getting the plastic gear out of the original 203 was easy enough, but opening up the 205 was a little more challenging. I had to unbolt the driveshaft and do all the work on my back underneath a stock-height truck....
Got it all put back together and took it for a test drive and I have a functioning speedometer again. Stripped gear pictured below.

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So I "finished" the swap, then the clutch started acting up. After about 80-100 miles it will not disengage when push the pedal. I tried checking the adjustment, but that didn't really help any. I gave up and took it to a local shop. Guy didn't really want to tie-up a rack, but suggested drilling a hole in the bellhousing to take a closer look and see if the flexplate bolts had possibly backed out. After that he started thinking that I have the wrong throwout bearing. He offered to come by my place and help me figure it out if I would pull the transmission. It seems like I have an 85-87 bellhousing and clutch fork and apparently they use a different throwout bearing. Anyone ever run into this problem before?
 
k10klub said:
So I "finished" the swap, then the clutch started acting up. After about 80-100 miles it will not disengage when push the pedal. I tried checking the adjustment, but that didn't really help any. I gave up and took it to a local shop. Guy didn't really want to tie-up a rack, but suggested drilling a hole in the bellhousing to take a closer look and see if the flexplate bolts had possibly backed out. After that he started thinking that I have the wrong throwout bearing. He offered to come by my place and help me figure it out if I would pull the transmission. It seems like I have an 85-87 bellhousing and clutch fork and apparently they use a different throwout bearing. Anyone ever run into this problem before?
Click to expand...
I don’t think your bell housing is 85-87.
if it was it would have a hydraulic slave mount. I know there are 3 different height throw out bearings, but what’s strange is it worked for a hundred miles. You would expect if it was too short it would never have worked. I would try to get a mirror or camera phone to look in the fork hole while someone works the clutch. See if you can see what’s happening
 
Fastereddie said:
I don’t think your bell housing is 85-87.
if it was it would have a hydraulic slave mount. I know there are 3 different height throw out bearings, but what’s strange is it worked for a hundred miles. You would expect if it was too short it would never have worked. I would try to get a mirror or camera phone to look in the fork hole while someone works the clutch. See if you can see what’s happening
Click to expand...
I'm wondering if my clutch fork jumped off of the ball stud.
 
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