1995 k3500 suburban xcase to np205

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leeezard7

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this is a custom ordered x sheriffs truck from a rural community. it was ordered as a 1995 1ton 4x4 454 tbi 4l80e g80 suburban. only weak link in the system is the transfer case. its the aluminum housing unit and works fine. i have a 1982 np205 from behind a th400. from everything i have read and looked at under the 82 truck then back under my 95 truck it looks like it will work. the th400 np205's were 32 spline inputs and the 4l80e is as well. it appears the bolt pattern on the th400 adapter will bolt to the 4l80e as well? then i just have to make a vss for the 205. has anyone tried this? were they successful? any snafu's any of you can think of before i tear it down? thank you for your time and responses in advance.
 

leeezard7

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plz let me clarify that last question... im not worried about the vss problem but has anyone done the 4l80e to 205 swap?
 

LoudnLifted88

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if the transfer is from a 82 gm the front driveshaft drop is on the pass side and the 95 is a drivers side drop so it wont work
 

leeezard7

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i also have a ford np205 divorced unit. that would be the correct side drop but need to see if i can use the th400 adapter on the ford unit somehow. ill look at it tomorrow to verify.
 

outalne94z71

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you do realize you should have the borg warner t-case and those are almost as strong as a 205.

that said, the divorced ford 205 is great if you are going sas with a 2wd trans but other than that you are asking for a nightmare to get it to mate up


what is the gvw on that burb? from what i understood they were still only a 3/4 ton burb but had the ff rear
 

leeezard7

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it states 9200gvw and has ff 14b and extra leafs. i have compared it to a 2500 burb and thats the only differences i can tell.

edit; a buddies 1994 2500 4x4 454 4l80e burb has a 14sf and a 241c. so not all the same.
 
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leeezard7

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what is the borg warner called? 241? 243? mine is a floor mounted shifter not the dash push button.
 

leeezard7

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if the transfer is from a 82 gm the front driveshaft drop is on the pass side and the 95 is a drivers side drop so it wont work
i guess i could install the dana 60f out of the same 82. but if i was going to go to that much trouble i would just install 5 ton rockwells in it and call it done. :)
 
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