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To marry the 700-R4 to your NP-205 you will need to change the TC input shaft to 27 splines. You will also need the adapter from a TH350 that had a 205 behind it. You will also need the 27 spline coupler or power sleeve as it is sometimes called, to mate the trans output to the TC input shaft...

Refer to the TM doghead posted. You will see the converter will stay with the trans. If it slides off the trans, use the turn and push method as decribed by on1wheel01. With the converter tangs set properly to the pump, you will feel resistance when turning the converter. When reinstalling the...

Both engine and ambient temperature is a big factor in how a diesel performs. Cold ambient air and a warm engine equals good performance. Cold air, cold engine, not so good. Ever notice how well you can breathe after a rainstorm? The air is saturated in oxygen. Cold air has more oxygen in it...

Unbolt the torque converter from the flexplate and pull the trans straight and level back from the engine. You will have to support the engine to keep it level with the trans or it will drop from the rear and ruin your day. The converter will stay with the trans. Keep a hand on the converter...

The old GM Powerslide 2sp trans could start a vehicle this way as it had both a front and rear pump. The driveshaft turns the rear pump sending oil to the torque converter and clutches. Once the clutches hook up, it completes the mechanical connection to the engine. Saw my dad do it back in the 60s.

Every truck you do looks the same to me. Over the top AWSOME!:jumpin:

The one component not included in the rebuild kit is the pump and it is more than likely the problem.

Once you get the broken extractor out, you may have to re drill the bolt all the way through using a bigger drill and extractor. If the bolt is that tight, a left hand drill probably won't help much. You may eventually have to drill out the bolt completely and Heli-Coil it. I did both starter...

speddmon fabbed up a welded riser for a short adapter on his 700-R4 conversion, it will also work for your short TH400 adapter.

Remove both the cover and driveshaft, this will give you plenty of room to work. There will more than likely be a ridge on the bolt where it twisted off. A small punch can be used to tap the bolt out counter clockwise. If that fails, use a left handed drill, You might get lucky and back it out...

The 241 had a problem with the chain stretching and slapping against the inside of the case creating a pin hole. Check out www.specialtytrans.com/...np241c_transfer_case_problems.hta

Thats a good score for a TC and adapter. Around here just a TC will run you no less than $150.00.

Thanks Marcus, It actually went pretty well. I used my Ryobi cordless drill, low n slow with plenty of cutting oil. Threaded the holes and installed the Heli-coils. The bolts threaded in nice and tight, and before I knew it, I was done. No blood loss or contusions were experienced during the...

Successfully Heli-coiled the starter bolt holes on the shadetree 09. One of the POs tried to use 3/8 threaded rod as starter bolts and buggered the threads so bad I had to drill out the holes and start over.

Good to hear you are OK, Darn shame about the 09 and Sorry for your loss, it really sucks.

All 80s GM transfer case outputs to driveshaft yoke are 32 spline.

Yup, and with the 700-R4s first gear ratio of 3.06 to 1, compaired to the TH400s ratio of 2.48, it will crawl pretty well off road fully loaded with firewood or whatever.

Oh BTW, If you can find the later model 205 with the 6 bolt round pattern, it is also a boltup with no driveshaft mods or input couplers needed. The 6 bolt 205 is hard to find as their production run was short and they were discontinued completly as an option.

That depends on how far the output shaft sticks out on the 700-R4 you have. A stock 700-R4 that had an NP208 behind it will have a long output shaft as they had the round 6 bolt adapter on them. So yes, you will need the 2" spacer and the shaft coupler sleeve to mate to it to the figure 8, or...

All 700-R4s are 27 spline. The spline count on your TH400 is 32, so the input on the 208 will be the same, 32. The 208 nor the 205 that was behind a TH400 will mate to the 700-R4 without changing the input splines on the TC to 27. If you really want a 205, you will have to find one that was...