What controller are you guys using? I have been on the phone with a couple of them and am still undecided. I have been reading a TON of info on this on the web. Gaaah my head is spinning. I am waiting for the GM oiler plug to show up and the transmission goes to the rebuilder. I have the fully splined shaft cut down to swap in also.
I am using the NW fabworks adapter for my fig 8 NP205 mount. It is 9/16ths thick and keeps the tall fig 8 adapter unmodified. The fully splined shaft is cut with this adapter in mind. Early 2x 4L80E's have the rear speed output. Most 4x4 versions don't have it and it is in the transfer case. The NP205 needs to be modified for this speed sensor or you can do what others have mentioned earlier in this thread. My trans is a 93 and needs the few ATRA technical service bulletin updates.
I also discovered lots of wear in my slip yoke 205. The input gear has bad spline wear. Original New Process input gears are not available and only Asian ones are made. I am also converting the rear slip yoke to a fixed yoke with a kit from Offroad designs.
http://www.offroaddesign.com/catalog/transfercaseparts.htm
The fixed yoke NP205 in my truck now is a version that is not as desired as others. It is a front output synchronized version. It is currently making noise when I turn a corner and or brake. It sounds like splines bumping. I read it was used for the early 80's and did not fly. It was for auto hubs and you cannot get the bushings for them. Non syncro'd front outputs use bearings and can be rebuilt. This straight non syncro front output is the desired NP205 to use.
To tell the difference... The Syncro version, look at the big round AL cover on the back. It will be fully cast and you CANNOT see the back of the steel bearing that supports the front output shaft. It is just a raised round casting. The cover all one solid piece.
The desired and better version, looking at the same cover, you will see a machined hole through the cover center and the steel bearing back will be visible. Most likely lightly rusted and definitely looks pressed in. I believe all CUCV's came with the desired version except they also have the slip yoke feature which can be converted easily to a fixed yoke.
The poster with all the output shafts shows one to use for the NP205. It says 9 1/4 long. This will not work. At least with the fig 8 adapter. You want the fully splined 8 + inch shaft that offers unlimited choices on trimming and makes sure you have full spline engagement with the transfer case input no matter what you choose to do. That's what I bought and with the 9/16ths thick NWfab adapter, my fully splined shaft OAL (***UPDATED***) is 6 3/4 sitting on the bench up to the end of the shaft. OR with the NWfab adapter on the trans, the shaft should stick out to 4 1/4 +/- a 1/16th from the adapter to end of shaft. This length will allow full contact with the NP205 input gear collar with about an 1/16th of trans splines sticking past the rearward edge of the splines in the 205 input collar. (***END OF UPDATE*** There is a shallow dead space past the splined 205 collar. Subtract 9/16 more off the OAL of the fully splined trans shaft if you machine the adapter and go that route. The NW fabworks adapter was 149.00 Easy for me as the closest machine shop is nearly 2 hours away.
The later short (in height) NP205 adapter has the feet cast forward and hits the 4L80E bottom cover. Avoid this short mount. It cannot be used unless there is a spacer between the trans case and the adapter. I will triple check all this and post any updates or corrections. I will post some pics also.
I am leaning towards the BEC Quick 1 trans controller. US shift.
http://www.usshift.com/usq1.shtml
And these guys, 4l80E simple shift. A brand new product. I am cautious of new stuff. This is compushift.
http://www.transmissioncenter.org/compushift_4l60e_4l80e.htm
I have read that TCI is a relabled US shift that has been detuned some. Some of the info I found was a couple years old. It's the internet right.
Good thread....