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How to get my 205 transfer case (32 spline) to mount with my TH400?

Discussion in 'OffRoad Design' started by PetaKane, Apr 14, 2003.

  1. PetaKane

    PetaKane 1/2 ton status

    Apr 17, 2002
    Likes Received:
    Oklahoma City OK
    I've got an 89 transfer case that I wanna put behind my TH400, that originally had a 208 case. Do I need to get a longer output shaft in the tranny, or get a shorter output shaft for the tcase? Or can I use either the 208 or 205 adapter with no problems?
  2. Stephen

    Stephen 1/2 ton status Moderator Vendor

    Sep 15, 2000
    Likes Received:
    Carbondale Colorado
    You can put a short input in the 205 and bolt it to the 208 adapter. You'll have to cut a notch in the adapter flange for the shifter but it works. The only problem I see is the housing is shorter so you may have some pan clearance problems between the TH400 pan and the front output assembly. And you'll have to rig your own shifter pivot.

    Another solution would be to get the later model adapter housing for it that's a little longer. Then you would leave the long input gear in there and it would set up just like it did in the '89 truck. We can still get those housings new so if you can't find one, let me know.

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