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Old 08-14-2018, 04:24 PM   #101
sweetk30
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Re: Rebuilding my 1977 plow truck

what trans are you running ?

th400 = 32 spline
203 = shortest tail shaft length .
205 fig 8 style next longest .
late 205 round 6 and 208 and 241 longer tail length .

th350 27 spline
203 AND 205 take same tail shaft length .

adapters are specific also .

and drive shaft lengths are different as is the shifters .

but i am sure you know this stuff .
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Old 08-14-2018, 04:54 PM   #102
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Re: Rebuilding my 1977 plow truck

I am running a th350. I really didn't know anything about doing this but I am learning. The guy I ordered the 205 from is very good on these. But he wasn't sure on the specifics for each truck/trans combo for shaft differences. His exact words were" no body ever calls me back and lets me know if any of the shafts need to have lengths changed" I bought a complete package from him. It has the transfer case with shifter, adapter and coupler.
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Old 08-14-2018, 05:00 PM   #103
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Re: Rebuilding my 1977 plow truck

that package deal will get you real close .

once its all in you will need to have the drive shafts reworked for the overall length . otherwise your good to go .
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Old 08-14-2018, 05:13 PM   #104
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Re: Rebuilding my 1977 plow truck

the sad thing is I just had a new rear shaft built for this truck and now I will have to send it back in to have it changed
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Old 08-28-2018, 04:10 PM   #105
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Re: Rebuilding my 1977 plow truck

Got the 205 transfer case on Monday, started install on Tuesday morning. It actually is a pretty straight forward easy install. the differences that I ran into are: driveshafts---front needs to be shortened, rear has to be longer. They are on the way to the driveshaft place as I write this. I should have them back Thursday or Friday. The speedo cable is on the opposite side of the tail shaft, in my case it was long enough to rerouted and put back on with no problem. The shifter lined up nicely in the hole, it does hit just a bit when going into 4 low. I could have bent the shifter or cut a bit of tin to make it clear but since I never use low range and it does go into low I decided to leave it well enough alone. The boot is a bit off center and doesn't fit tight on the top. I am thinking about buying a shift knob with the correct pattern on it. The crossmember and mounts lined up with no modifications. All and all I think it is probably the best way out of the NP203 problems without replacement of the trans.
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Old 08-28-2018, 06:02 PM   #106
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Re: Rebuilding my 1977 plow truck

make it clear . if you need 4w-low it can pop out from driveline twist in the engine/trans mounts to body flex .

looks like a super clean rebuild of that unit .

only thing i would have done if mine since i have had it done and LOVE it is a twin stick conversion and modifyed shift rail . gets you 2wd low and front wheel only high / low option also .

the 2wd low is so nice moving trailers around .
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Old 08-28-2018, 06:21 PM   #107
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Re: Rebuilding my 1977 plow truck

^x2
I had a dual home made shifter on my 203 transfer.
It was nice to use the high or low without the 4wheel drive.
here is a link of how to dual stick the 205. if you are interested.

https://www.pirate4x4.com/forum/gene...ick-cheap.html

Nice work It looks good
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Old 08-29-2018, 09:25 AM   #108
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Re: Rebuilding my 1977 plow truck

It hits just a bit when I put it in 4 low but has clearance when it is in gear. I have never used low range in the 35 years I have owned the truck. I don't even put a 1000 miles a year on the truck and all I ever use is 2 & 4 high. The guy that I bought this from was very helpful and honest. He does a lot of them from the way it sounds.

Last edited by CSHADES; 08-29-2018 at 09:29 AM. Reason: additional info
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Old 08-31-2018, 09:12 AM   #109
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Re: Rebuilding my 1977 plow truck

Got the driveshafts back yesterday. installed and truck is driveable once more. It all seems to work good.
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Old 10-04-2018, 11:34 AM   #110
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Re: Rebuilding my 1977 plow truck

Couple of weeks ago the tire shop/scrap guys across the street were scrapping a 78 chevy 3/4 4x4 I walked over to see what wheels were on it and buy them if possible. I ended up with all 4 steel wheels for $40. As I was looking at it I noticed that it had a vent shade on the right side door. I hadn't seen a set of those in a while. When I was in the dealership I put 100s of these things on, I used to put them on all of my squares. I thought it would be a good addition for the 77 but there was only the one and it wasn't that nice so I didn't bother with it. I went to our last swap meet of the season last weekend and lo and behold on a table was not one but two brand new pairs of vent shades for $10. I bought them without even trying to get him to go lower, he didn't think he would sell them. So on Monday ran a load of tires to the dump and decided that I would install them when I got back to the shop. I tried to find some stainless screws in town but of course no one seems to keep #4 x 1/4 in stock. I put them on with steel screws for now and ordered the stainless ones. While I had it in the shop I also decided it was time to do something about the radio, the volume control would cut out when I tried to adjust it. it was very annoying, I pulled it out, removed the covers and sprayed the controls with contact spray. Put it back in and it works perfect now. I also decided that I should get some wax on the old girl before winter. I picked up some wizards paint sealant and applied that after washing the truck. It is looking pretty good for going on its third winter since paint. Next up--blasting and repaint of the replacement wheels.
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Old 10-04-2018, 05:17 PM   #111
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Re: Rebuilding my 1977 plow truck

Truck looks great! The vent shades are a nice touch!
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Old 10-10-2018, 05:48 PM   #112
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Re: Rebuilding my 1977 plow truck

I’ve always liked those vent shades. They’re cool looking and functional. I’ve had them on every square I’ve had.
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