400 turbo output shaft vs. transfer case

[TLoz]

Hi,
Just tried to bolt my 400 turbo(with 203 adapter) onto a 203 transfer case. Guess what, the tranny output shaft was to long. Am I correct to assume that the output shaft on a 400 turbo that was bolted up to a 205 won't work with a 203, even using the 203 adapter? If that's the case, looks like I get the pleasure of taking the tranny apart again. Lessons learned.

[FormerMember]

That is correct. They use a different length stick out.

[FormerMember]

It was posted here.

The two on the left are t-case input shafts used with Th400's. A 205 typically used the second one from the left where the 203 used the first one on the left.

You could build a spacer, which might be less work than doing the output shaft on the trans. I've also successfully cut down the output shaft on the trans.

[TLoz]

Thanks for the reply. I'm going to look into cutting the trans shaft. I'll take some drop checks between the output/input/adapter to make sure I have enough engagement. The 400 is out of the truck, so I can mask off everything use a cutoff saw and then deburr. Worse case, I'll have to take the trans back apart.
Thanks, Tom

[FormerMember]

Originally Posted by TLoz

Thanks for the reply. I'm going to look into cutting the trans shaft. I'll take some drop checks between the output/input/adapter to make sure I have enough engagement. The 400 is out of the truck, so I can mask off everything use a cutoff saw and then deburr. Worse case, I'll have to take the trans back apart.
Thanks, Tom

I have one apart if you need me to take measurements. In fact, this is a Cadillac Th400 that I cut down.

[TLoz]

G,
Thanks for the offer. I'm still doing some thinking. Found a 400/203 output/input shaft for $75. I figure that a gasket/rubber kit will run me about $28.00. Add a six pack on top of that along with a quiet evening and it'll be done. I should be able to sell the 400/205 shaft for around the cost of replacing. Things to ponder over.
Thanks, Tom

[FormerMember]

Originally Posted by TLoz

G,
Thanks for the offer. I'm still doing some thinking. Found a 400/203 output/input shaft for $75. I figure that a gasket/rubber kit will run me about $28.00. Add a six pack on top of that along with a quiet evening and it'll be done. I should be able to sell the 400/205 shaft for around the cost of replacing. Things to ponder over.
Thanks, Tom

That works, too.

I've done enough of them at this point, where it's an easy process.