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Author Topic: 1993 4x4 3500hd parts help  (Read 4053 times)

crewcab 4x4 3500hd

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1993 4x4 3500hd parts help
« on: May 09, 2010, 07:08:21 PM »
Hey everyone new to the site today 5/9/10, I have 1993 Gmc Crewcab 4x4 3500hd, Monroe truck had a part in building this truck and so did Tulsa truck. My problem is it has 6.5 diesel with nv4500 and np205 transfer case mated to it, and they made a special coupler to mate the 35 spline out put shaft on the trans to the 29 spline input shaft on the dodge transfer case, and my coupler stripped all the splines on the trans side (35 splines). Does any one know of a machine shop that can make something of this sorts?   Tulsa truck doesn't have any more and the machine shop they used is out of biz... The only other thing I can do is go to a divorced mount transfer case....


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Re: 1993 4x4 3500hd parts help
« Reply #1 on: May 09, 2010, 07:39:13 PM »
First off welcome to the forum...your situation is exactly why we have this 3500HD forum. That said I hope someone out there has some ideas.  Can I suggest contacting the folks at the link below:

Just a suggestion and hope someone reading this post can help you.



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Re: 1993 4x4 3500hd parts help
« Reply #2 on: May 10, 2010, 10:22:40 AM »
Yikes! My experience with the 29 spline Dodge case is that the 29 spline stuff is SUPER hard to come by (ONLY came in Dodge heavy duty 5 speeds, all else is 23), and needing to have one side broached to 32 spline adds that much more complication.

My suggestion for ease of parts would be to find a 32 spline input shaft from a 205 that was mated to a 400 trans (which are real easy to come by), but that would still require an adapter... Does your t-case utilize the Dodge adapter to the 4500? should have the GM input for the 205.

Theres many styles of input shaft for a 400/205 so I'd do a little google search first and see if theres anything that'll slip right in for ya.

One last suggestion... I have a Dodge 4500, and would only need to swap the bellhousing and input shaft to the GM parts (direct swap) that would use the 29 spline on both t-case and trans. I'm sure that the reason yours failed on the trans side, was that the stock 29 spline coupler being broached to 32 splines had weakend the coupler by not having enough material left to support the splines. Or just poor spline engagement due to improper spline depth/pitch from the initial machine work.

EDIT: I just re-read your post and noticed you have a '93 trans, Dodge parts only interchange with '96 and newer GM 4500's. So I'd go back to the 32 spline input idea. One that would use a sleeve/coupler like you have now might let you use your current adapter since the two sleeves (32 and 29 spline) are almost the same length if I remember correctly.

« Last Edit: May 10, 2010, 10:37:00 AM by Raymo »
'94 3500-HD, Cummins, Getrag, NP205. Shortend rear frame with a Pickup Bed. Dana 60 front, stock 80 rear.

'03 2500-HD 8.1 and Allison



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