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Old 12-14-2008, 07:54 PM
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Transfer case not going on.

I have a Chev 1 ton 4x4 that developed a leak from torque converter, found a rebuilt TH400 w/ converter, pulled old ones out, got tranny in but I'm struggling with the torque converter. I can line up everything, spline shaft goes on, bolt holes are lining up but it gets about 3/4" from where it's supposed to be but something is hanging it up from going all the way on. I could stick bolts in and slowly snug it up but I'm afraid that might bust something. Any ideas of what might be hanging me up? I made two pilots (cut off bolts) stuck in the bolt holes that are going into the clearance holes so I know I'm lined up right but it just won't budge on. Help!

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Old 12-14-2008, 08:18 PM
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Are saying the torque converter is not fully engaged into the transmission when you lift the transmission up to the engine?

The converter is holding the trans back from the engine?

You will break stuff if that is what is happening and you bolt it up tight
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Old 12-14-2008, 08:41 PM
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Quote:
Originally Posted by Crosley
Are saying the torque converter is not fully engaged into the transmission when you lift the transmission up to the engine?

The converter is holding the trans back from the engine?
...
Yes, that's what I'm saying and no, I don't want to break anything. Tranny/engine is supported with a floor jack and the transfer case is on a tranny jack. I don't have bolts in the holes, I have bolts in with heads cut off just to make sure I'm located right.
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Old 12-14-2008, 08:54 PM
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The converter goes into different series of splines. You should have installed the converter into the trans first, then put the trans into the truck.


You need to rotate the converter back and forth with light hand pressure, pushing it inwards. Once you felt it go into one spline, you likely thought that was it....but it needed to go more, by the same rotating movements. I think it would be hard to do it with the trans somewhat installed. When the converter is in all the way, there is no reason to pull it in with bolts...except for the dowel pins. You always need to keep checking the convertor to see if it still spins easy, as you bolt the trans to the engine.
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Old 12-14-2008, 09:04 PM
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I really blew this thread, it's not the torque converter that's the trouble, it's the transfer case. The transfer case isn't going on the tranny. Torque converter and tranny are installed fine. The transfer case is on the spline shaft on tranny jack but it's 3/4" away from the plate attached to the end of the TH400. 2 cut-off bolts are lining up the transfer case with the clearance holes in the plate but it won't go past where it is.
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Old 12-14-2008, 09:16 PM
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Put up some more info... Which transfersase??... and is the "new" trans from a 4x4 that used that same model of transfer case?

I have a th400 bolted to a NP cast-iron 205 Tcase. That 205 t-case is unique as it has a FEMALE input spline. A same-year 205 for a th350 uses a male input.

Now, I also used a 2wd TH400 in mine. The output shaft on the trans is a different part than a 4wd shft, but the differences don't affect anything.

What are you running for t-case?
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Old 12-14-2008, 09:19 PM
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Also, do you have the trans in "park" and the T-case in gear? That makes it easier to align the splines as you twist the t-case as you try to shove it forward.
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Old 12-14-2008, 09:33 PM
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I'll have to hook up the shift linkage to the tranny to know what it's in, I don't think it's in park. I'm not sure about about what the transfer case is positioned in either. I know the yoke would spin free until I got it on the spline of the tranny, then it was real sluggish turning both directions.

I'm not sure of what transfer case this is. On the back, there's a cover plate with 8 bolts holding it on, behind the front drive shaft.

When I picked up the rebuilt tranny, the guy took off the shaft of my old tranny and put it on this one as it was set up for a two wheel drive before.
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Old 12-15-2008, 12:32 AM
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The transfer case is a 203. Shift pattern front to back is Low-lock, Low, N, H, H-lock

Last edited by Raybob; 12-15-2008 at 10:33 AM.
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Old 12-15-2008, 06:54 PM
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The tranny was for a 2wheel drive but it was re-shafted for a 4x4 the day I went to get it. I just spoke to the guy I bought it from and asked him how far the shaft was supposed to be sticking out from the tranny. He measured another for a 4x4 at his shop and said 1-3/8". I measured mine and it's 2-1/8". Evidently, there's my 3/4" holding it up. I could bring the tranny back to him and he could re-shaft it with the shaft he has there but he's very far and the tranny is in already. I suggested cutting off this shaft 13/16" and he said that would work. If it didn't, bring it back to him and he'd re-shaft the tranny with the shaft he has. Guess I need lots of cut-off disks for my disk grinder.
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Old 12-15-2008, 07:27 PM
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there are 3 different lengths of out put shafts of the 4x4 design for the t-400..

As I recall the 203 t-case shaft is the shortest.
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