Need help w/TH350 Output OD ???'s

[DizturbedOne]

I pulled an NP205 from a junkyard on half price day. Got it off of a TH350 in a 74/75/76 K30 pickup

My 76 Jimmy has a TH350 in it with an NP203 mated to it. I pulled the trans and tossed the 203 to the side (shifter issues anyways), and it seems as if the coupler to join the TH350 to the new 205 has a smaller ID than the OD of the 350's output shaft... I have no calipers to be sure, but it DEFINITELY looks so. (I already cleaned up a couple marred teeth thinking that was the problem, then went over it with a crocus cloth)

I thought the TH350 4x4's only had one shaft?

I really need this thing DONE and put back together ASAP (it's parked at a friends)

Any ideas what could have happened here?

 

[chalet2506]

If it came from a K30, it most likely wasn't from a th350. K30's had th400's. That could be the problem as 205's are different for the 2 tranny's.

If it did come from behind a th350, did you pull the adpater too? th350/205 and th350/203 are different adpaters.

 

[DizturbedOne]

Yeah, I know the K30's had 400's in them originally, but the one I was under had a TH350. When I pulled it I was looking at transmissions and t-cases, not trucks.

It was definitely a TH350, and yes, I have the adapter that came with it also. They are BOTH 27 spline count, but the ID of the adapter is definitely a bit smaller, I would say about .010 or .015 or so.

Is there a one-off TH350 (maybe a Buick pattern one or something?) with different 205 t-cases? This is really stressing me out, it took over a month to get this thing back, and now I can't send it out to be built.

 

[Greg Ducato]

All 350 4x4's had the same spline count, it is the same as the 2wd version as well. Check the splines closely, make sure they are not twisted slightly from end to end.

 

[Hogback Fabrication]

All of the TH350 outputs are the same size and 27 spline is 27 spline, it should fit. Make sure it's not rusty or dirty.

 

[DizturbedOne]

I'm pretty sure it's twisted. Been trying to source another one. There are 3 teeth that have spacing that looks "off" compared to the rest. Thank you for your time you guys.