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Old 10-14-2007, 10:01 PM
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Mating 4L80E to NP205 transfer case

Guys,

I need to know if any of you have done the above. The best I can tell there are two types of 32 spline inputs on the NP205; short and long. The 4L80E has two shaft lengths; two and four wheel drive. I have read that you have to use the long NP205 input, which I have. However, I can not find info as to if the four or two wheel drive output shaft on the tranny is needed. I have come to the conclusion it takes a 2wd with about 1/2" cut off the end. However, I am wondering if it is actually the 4wd 4l80e output is needed and that the 2wd works with the short 32 spline NP205 input.

I am going to use the TH400/NP205 adapter with reindexing in the conversion.

If anyone can help with this I would greatly appreciate it.

Thanks,

Chris

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Old 10-14-2007, 10:08 PM
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Sounds like it will work. I would think the 2wd shaft that has the long spline could be cut to the exact length you needed.
I would have to have the adapter and T-case or the correct TH400 output shaft to figure it out.
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Old 10-14-2007, 10:13 PM
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If what you have planned doesn't work out then try out Advance Adapters. They have just about anything you'd need to perform the conversion you're talking about.

http://72.20.96.178/commerce/ccc1026...e-adapters.htm
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Old 10-14-2007, 10:44 PM
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Quote:
Originally Posted by Blazin72
If what you have planned doesn't work out then try out Advance Adapters. They have just about anything you'd need to perform the conversion you're talking about.

http://72.20.96.178/commerce/ccc1026...e-adapters.htm
Yeah, they have about everything, but the cost are kindof prohibitive for my pocket book. If worse comes to worst, then I could go that route.

Thanks,

Chris
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Old 10-14-2007, 10:46 PM
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Quote:
Originally Posted by jakeshoe
Sounds like it will work. I would think the 2wd shaft that has the long spline could be cut to the exact length you needed.
I would have to have the adapter and T-case or the correct TH400 output shaft to figure it out.
Yeah, if I had a pile of parts, I could figure it out. Since I drive this truck I am trying to round everything up and take it to a shop for a one or two day turn around. I just cant do it that fast without help....which I dont have available right now. I dont want to buy anything I dont need.

My concern with the 2wd output is that the splines are not that long. If I had to cut alot off, engagement would be conprimised.....not good for a 600ft/lb diesel setup .
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Old 10-14-2007, 10:49 PM
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Quote:
Originally Posted by TurboS10
the cost are kindof prohibitive for my pocket book.
I agree there, just wasn't sure if you knew about them or not
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Old 10-14-2007, 10:51 PM
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Is a divorced transfer case setup an option?

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Old 10-14-2007, 10:56 PM
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Quote:
Originally Posted by Crosley
Is a divorced transfer case setup an option?

Well, it is, but I dont have one. The divorced NP205's bring good money and would require a good deal of drive shaft and shifter fabrication. I just spent a chunk putting the 12V cummins in the truck and I really need to keep cost as low as possible on this tranny swap.....I know, I know....wrong transmission for low cost, but I need OD!
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Old 10-14-2007, 10:57 PM
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In the above pic is a 4l80E 2WD output shaft, but there is another type with a longer spline also used on the 2WDs that the splined portion is about twice as long as the one pictured.
This type could be cut down to almost any length needed, or any trans shop should be able to source a good used 4wd output shaft.
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Old 10-14-2007, 11:03 PM
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There are quite a few different length 4L80E shafts, and also different configurations depending on year (lube flow changes).

There is a 3.75 and 5" 4x4 output shaft for 91-96 models.
There a 7 7/8, 8 1/8", and 9" 2wd shafts.

Maybe that will help.
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Old 10-14-2007, 11:04 PM
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While I have your attention, this is what I know I have to work through so far. Anything else come to mind?

What I have found so far:

-Overall length is 1 9/16" longer so driveshafts could need change(have a decent amount of adjustment)

-NP205/TH400 adapter will need slight machining for transmission side.

-Will need Long 32 spline NP205 input, which I have. Still working on which output shaft to get.

-Going to have to fabricate flywheel cover for cummins engine plate.

-Using transgo full manual valve body with B&M unimatic shifter.

-Debating setup of variable vacuum for line pressure modulation.

-Speedometer should work since it is in transfer case

Jakeshoe, where are you from in Texas. Want to do a transmission build/swap?
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Old 10-14-2007, 11:07 PM
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Quote:
Originally Posted by jakeshoe
There are quite a few different length 4L80E shafts, and also different configurations depending on year (lube flow changes).

There is a 3.75 and 5" 4x4 output shaft for 91-96 models.
There a 7 7/8, 8 1/8", and 9" 2wd shafts.

Maybe that will help.
Are these total length or from the rear of the case? From what I can tell I just need to duplicate the TH400 shaft length on an 87 chevy, which should be the long input on the NP205. If you know those lengths off the top of your head, then picking the 4L80 shaft should be easy.
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Old 10-14-2007, 11:13 PM
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OK,
Here's something to think about.
You are mentioning using the long input 205. However a 4L80E is longer than a TH400, so your overall length would come out better with a shorter overall transfer case length.
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Old 10-14-2007, 11:16 PM
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The best method for me to figure it out would be to have the measurement from the back of the trans to the end of the output shaft for the Th400 used with your transfer case. Then I could get tell you which output shaft you would need because I can measure a 4L80E in the shop.
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