Thanks, that all makes sense. Feels like there's something internal allowing too much slop and preventing full engagement.
I didn't know about the older coarse spline shaft. So, my 79 K5 Blazer that has that cast-iron HD four-speed and the cast-iron NP 205 transfercase is 10 spline? I was kind of wondering if there were different standards pre-80s.
It wouldn' be worth all the effort to swap in a transfercase. I've done enough 700R4-removal conversions back in the early 80s. Changed a lot over in diesel trucks - to TH400s with mechancial modulators.
I'm hoping that there's some way to perhaps weld some parts together inside the transfercase to make it 4WD all the time. It will never be driven on the road again - it's strictly a farm snowplow rig. If it's too much work to fix, it would be easier to take the plow off and mount it on another Blazer or Suburban - I have many good runnig 4WD Blazers and Burbs - partially retired and parked out in my field.
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Today's Featured Article - Choosin, Mounting and Using a Bush Hog Type Mower - by Francis Robinson. Looking around at my new neighbors, most of whom are city raised and have recently acquired their first mini-farms of five to fifteen acres and also from reading questions ask at various discussion sites on the web it is frighteningly apparent that a great many guys (and a few gals) are learning by trial and error and mostly error how to use a very dangerous piece of farm equipment. It is also very apparent that these folks are getting a lot of very poor and often very dangerous advice fro
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