SM465 10 spline output shaft wear and driveshaft slip yoke wear

[zac]

Pulled the SM465 and NP205 from my '72 suburban parts truck. The output shaft shows significant wear on the splines. I have a new sleeve or collar that connects the trans output to the transfer case input. The transfer case shaft shows no wear and the sleeve fits tightly with no play. But there is a lot of slop on the trans output shaft. I know this is a common problem. How difficult is it to find a good SM465 4wd output shaft? I have a '70 K10 burb that these parts will go in. Based on the slop and clunking in the driveline the output shaft in there is probably worse.

Also, the rear driveshaft slip yoke has a lot of slop. My understanding is that the splines on the shaft wear and it has to be cut off and repaired with a new slip yoke by a drive shaft shop. Are there any other options? My truck is just a decent stock driver, doesn't need anything special. Thanks

[Ironhorse]

zac, PM sent

[OLDGREY]

I have a 72' jimmy that had the same issue. I ordered a used shaft from Novak for around $80. It had some wear but not nearly as bad as the one I had. As far as replacing the old one, it wasn't to bad. I was doing a full rebuild on the tranny anyway. I also ordered a new SM465 to NP205 coupling.

[Lemield]

What a coincidence! I had a vibration noise in my drivetrain of my K20. I thought it was my NP205 transfer case. Pulled the case and saw the actual problem....the output shaft of the SM465 and the coupler are trashed. There is even some nasty wear on the input shaft of the NP205. Both the transmission and the transfer case are at a local transmission shop right now being gone through.

According to the trans shop, this is pretty common for these old SM465/NP205 combinations.

[OLDGREY]

Wow! That output shaft is hammered! I'm in the middle of rebuilding the 205 and that side of the coupling is in good shape. I wonder why one side would wear so different than the other?

[Lemield]

It is pretty jacked up....I was hoping the noise was in the transfer case....guess not!

Your vehicle in your avatar picture is the same color as my K20.....is that the one you are working on?

[OLDGREY]

The one in my avatar is one I picked up on Craigslist for $600. I bought it mainly for parts for a 69' c-10 short bed I have. I decided to put an engine in it and drive it. The one I'm working on now is a 72' jimmy 4x4. It also going to be a daily driver for the winter and camping. I can't imagine not having one of these in my driveway. There like a drug!

[Lemield]

Right there with you on that one! I got 3 of them....highly addictive!

[zac]

Hey Oldgrey:

I checked the Novak site, thanks for the tip. I noticed they also appear to have new ones for $135. My shaft looks almost as bad as the one pictured above. You said the used one you bought was pretty good. Good enough, would you say? Took care of most of the slop with the new coupler? I've got the driveshaft issue taken care of. Thanks.

[OLDGREY]

I put the new coupler on it and it barely had any side to side movement. I'm real sure it will last another 40 years. Plus I know how I drive. I'm not one for bashing gears or beating the crap out of it. I think you'll be happy with the one they send you.