I have a NV 4500 out of a 97 Chevy and an NP208 transfer case that is weak...... I know the NP205 was as close to bullet proof as they came. How many Spline Case am i looking for? and does anyone know what year, model, manufacturor would have had them in stock?

 

You need a 32-spline NP205 with a round pattern. Those came in 85-91 K30. Its still not a direct bolt up.... needs a spacer and/or a notch cut in the NV4500 for the shift rail.

 

the 208 isnt real weak. they where on the military trucks and i know a couple guys who plow snow with them. this weekend i also pulled a sled with a 208 in the hot street class. held up fine even with a transmission that only has 1 and 2nd dont need anything higher than that when pulling

 

Unfortunately my 208 is leaking fluid..... most likely just a seal but considered upgrading while i was there.....but im not totally against leaving the 208 in place either

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doesnt this transfer case need to be a passenger side drop as well? I found a 205 off of a 4l80E that would most likely be what im looking for and they want 600 for transmission and all. Seems reasonable except the transfer case is drivers side drop

 

idk all you have posted is 91.5 cummins chevy. if your chevy is pre 87 (91 for crew and blazers) then yes you have a solid front axle and need passengers side drop. if you have independent front then you would be looking at drivers side. but the 208 is from what i know only passengers side

 

My Chevy is an 86....... so that helps a bunch.... I need a passenger side drop. That is what my 208 is currently as well. I think that limits me to 85-87 K 30 chevy NP205. Where i was looking for an85 to 91. Unless its a 1 ton suburban which would have had the non independent front end.

 

whats wrong with your 208?