Speedo was inop. Put a new ratio adapter and vss. Spun up new vss with drill and works properly. Installed new assembly and snapped the square shaft on the new ratio adapter. What caused this?

 

Without knowing any specifics year etc. all we can say is it is an ancient Chinese problem:Sum Ting Wong.

 

It's a 91.5 4x4 auto np205 tcase. The truck is lifted with 33" tires and the color of the truck is silver. No Chinese problems here

 

When I put my new ratio adapter on I'm pretty sure it came with several "inserts" to match up to the tranny/transfer case you are using....universal set-up. I think I had to remove the one that came on the ratio adapter and slip in a square one to match the output on my TC.

If you tried to install it with the piece you show in the pic, It would bind and break as you tighten it down I believe.

 

It seems like mine was square too.

 

The one I put In had a square end that is now broken inside the tcase

 

I bet you can pull that broken square drive out with a needle or maybe even a magnet.
It should be a square drive. Try installing another square drive into it and see if it spins when you turn the driveshaft. Then check the length of it to make sure the last one was not too long and that is why it broke when you screwed it together.

 

If your having trouble removing the broken portion, its just as easy to remove the drive itself. The piece your adapter and sensor attaches to is also removable from the transfer case. Its simply threaded into the t-case housing itself. Once you have it removed you could also check fitment with your new square drive shaft and find wether or not you have interference with your adapter and speed sensor.

 

Where's the fun in that?

 

where do you buy these? cant find anywhere yet

 

Is this what you need? :

https://www.rockauto.com/en/catalog/...d+sensor,10634

...Mark

 

If you can not find a 1st gen part [or 2nd gen dodge part], contacting me usually gets you options...

PM if you like.

 

i investigated a bit more on mine.
removed the whole thing and disassembled the ratio adapter.
not much inside!
looks like the square shaft snapped because the output gear was seized in rust, it is just spinning in a brass bushing.

so i cleaned and wrapped a strand of epoxy soaked fiberglass around a piece of 3/32 square keystock to match the round diameter needed and will fix it in the gear shaft. migth work! ill let you know.

otherwise, the reducer is what in was asking for if someone as a link to buy one if ever my repair doesnt work

note the square shaft was originally 2mm but 3/32 ia just 0.009” under

 

i bet i could possibly remachine the round keyed part to fit the keytock in and weld it but im too lazy today... ill see how it goes

 

Hey Kriss if you go to PACT Transmission and type ... ratio adapter small parts kit ... in the search bar I think that is what you are looking for. I bought the kit several years ago and if I remember correctly only one or two of the parts work for our application, but then you have extras that you can put in the junk drawer that you will never use ...lol