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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