"Transfercase splines to fit a light duty four-speed manual overdrive (New Process 833) or a light duty turbo-350 or 700R4 auto are 27 splines.
Now, I've got this truck with the full-time 4WD NP 203 transfercase mated to a turbo-350 trans. Anybody have any idea what splined shaft it's going to have?"
You answered your own question... The THM-350 and the 700R-4 share the same tranny output spline congiuration.
The THM-400 and the later 4L80's share a heavier shaft/spline configuration.
First of all, have you cleaned and lubed the 4X4 shifter and adjusted the linkage rods?
If that doesn't help, it's really NOT too tough to access the lockup parts on the UPPER shaft at the rear of the unit.
The problem may be as simple as a worn fork, or the parts added to eliminate the lockup function MAY be torn up.
There were GOOD kits, using a one-piece steel splined part to accomplish the "full-time 4X4 defeat" function, and less tough kits that used 4 toothed blocks to replace the spider gears in the interaxle differential. You may want to grab a book and tear the back upper cover off of the case and see what's in there before going to all the trouble to change out the entire transfer case.
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