trans to t-case coupler

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Oct 23, 2009 | 04:50 AM

#16

NO_SPRK

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From: Santa Rosa, Ca

Quote:

Originally Posted by RonA

When i first installed it i was in the 700hp range.I checked it about 2 months ago and it was still fine. I turned the od of both sleeves concentric to the id and the same size. I cut them so that after cutting the teeth in them they would be the right length when mated together. I bored a set of jaws in the mill and cut 4, 45 degree slots 90 degrees apart( like slices of pie). This leaves 4 slots and 4 matching bosses that will mate together when placed end to end. I then took a piece of 3/8 wall tubing and bored a counter bore in in deep enough for the entire sleeve to slide into it and bottom out. I then made a cap for it and welded it in place. When done I slid it back on an arbor and re-cut the od and ends for balance.It only has about .001 clearance on the id and the ends. I used an end mill with .03 radius so there wasn't a sharp corner in the bottom of the slots. when mated together the two halves tend to not force each other apart and stay concentric. The outer tube just keeps them from seperating. Hope that makes sense.

that makes perfect sense. im very interested in this because i dont have an extra 600 to blow on a t-case when mine is perfectly fine. what i dont understand is how people say they cant hold up but no one talks about them breaking and its only a 6 spline difference. not like a old 10 spline to a 32 spline (chevy set up)

so did you have any issues on how each of the shafts are centered?

i think i sent you a PM, did you receive it?

Oct 23, 2009 | 06:52 AM

#17

bgilbert

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From: Terre Haute,IN

Quote:

Originally Posted by NO_SPRK

what i dont understand is how people say they cant hold up but no one talks about them breaking and its only a 6 spline difference. not like a old 10 spline to a 32 spline (chevy set up)

It's not the difference in splines, it's the size of the transfer case input shaft that is the huge difference is size. When comparing the two (29 vs 23) the smaller 23 spline input looks half ton gasserous

. But if it's still holding in Ron's high horse truck it may hold up to the power. Pretty sure he's even done boosted launches at the dragstrip with it.

Only thing is how much will he or a machine shop charge you for building a coupler?

Oct 23, 2009 | 07:14 AM

#18

roxxx

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From: North of Calgary Alberta

Quote:

Originally Posted by NO_SPRK

just finished a 5-speed swap on my friends truck made me think about converting myself but with the price of 29 spline NP205s it makes me think not!

so is there any reason why you couldnt get a custom 23 to 29 spline coupler to mate the two? there was lots of room around the trans and t-case output/input shafts.

did a search and didnt come up with anything

THANKS

It will cost you more to do a custom 205 than just getting a good one. I imagine were you are there is a lotta 4x4 shops and forums just start lurking on their forums heck if you were closer, I have a good one sitting here i would sell to you for what i paid for it

Oct 23, 2009 | 07:38 AM

#19

NO_SPRK

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From: Santa Rosa, Ca

I found one in oregon I can get shipped for 500. If someone would buy my 47rh or my 727 and 205 I'd buy it right now. I got a wad of cash but I keep crunching numbers and coming up real close if I buy a t-case. I found the 29spline coupler online for about a hundred bucks. I was going to cut the 2 in half and have them welded and then put a sleave over it with swiss cheese holes and weld those all up.

How much do u want for your 205? How do you like your clutch? That's the con o right? I plan on buying that one

Oct 23, 2009 | 11:07 AM

#20

kensmachine

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any one loooked at www nv4500.com

Oct 23, 2009 | 09:57 PM

#21

NO_SPRK

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From: Santa Rosa, Ca

Yeah. Not as much info as quad 4x4

Oct 27, 2009 | 11:36 AM

#22

RonA

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From: Browns Valley CA

Just so there is no confusion. The coupler I made adapts the 23spline 47RH output to my existing 29 spline 205 transfer case input. Yes it has held up to boosted launches and a couple of years of use. There is no reason for it to fail really. The coupler can probably handle more than either of the shafts.

Oct 27, 2009 | 02:09 PM

#23

Billut

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From: Birmingham, AL

Man, a picture of that set-up would answer all the questions, you wouldn't happen to have one would you?

Oct 28, 2009 | 09:44 PM

#24

RonA

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From: Browns Valley CA

This is what the maching looks like for the ends. These 2 pieces are the left over short pieces that I used to set up the milling op. When done the 2 mated halves sit inside a piece of tubing with caps welded on the ends to allow for only a minimal amount of movement.

Attached Thumbnails

Oct 28, 2009 | 09:52 PM

#25

NO_SPRK

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From: Santa Rosa, Ca

Sweet. Thanks for the pics that's what I expected to see

Dec 11, 2011 | 04:24 PM

#26

done_my way

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From: Boston, KY

The coupler in my gasser (23-spline) spit out the center internal snap-ring and has almost stripped the splines on one end. The shafts of the trans and t-case are fine. Soooooo, you guys whose coupler has held up, I applaud you, cuz they DO fail.

Dec 12, 2011 | 09:25 AM

#27

texsasdiesel

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i dont' have the awesome skills that RonA does so i just ordered one of these for my crew cab build

http://shop.shsdiesel.com/23-spline-...329COUPLER.htm

James