Yes sir I did exactly that. However, all 27 spline slip yokes are not created equal. The one I used was a factory issue very brittle cast unit. It appears to have been over-heated during my shade tree welding process, and it failed miserably. Also, the amount of engagement of what was left of the ZF output shaft leaves a lot to be desired. It is just not long enough to make a good engagement for shaft length necessary. No damage caused when it failed, just setback and another chance to learn something.


Round two, redesign.... it has taken me a few weeks to get back to the point of reassembly. I have made a few other improvements/modifications along the way.


1. Installed a shallow (car) oil pan from Summit Racing. Way better clearance for the front propshaft, no hammer whacks needed.


2. Two new propshafts, front is minus the double cardan joint. Not enough room to put it on the TC end, so I cut it out and lengthened a brand new Tom Woods custom shaft. (Now it's custom-custom) I think it would work fine on the differential end but was advised not to put it there. Most of the angle on the front setup is caused by the 2" Terra firma lift kit. Will need some caster correction in the future. Rear shaft is work of art from Tom Woods, it has double cardan joints on BOTH ends, really heavy duty.


3. Built and installed an electric motor operated center differential lock. I used a junkyard headlight motor from a Saturn. Great setup 'cause it has a hand wheel on the back of the motor so it can be operated with no power or in a malfunction situation.


4. New and improved connector shaft between the 4WD 4L65E and the LT230 TC. I guess I owe you a picture now, but long story shortened, it is made from a unmodified 1350 27 spline slip yoke (not GM style). On the TC end I welded a cut off (about 2" long shaft) end of a discarded propshaft onto the ZF Transfer Box coupling. (See stock picture below)
Between the two there is one 1350 universal joint. All this is stuffed inside the 4" tube adapter that bolts between the TC and transmission. The picture I plan to upload tomorrow should make my description clear as mud. In the interest of full disclosure, I was told by one driveline builder that this would not work, so he refused to build it for me. Not a problem for a Shade Tree, I gotta find out for myself.




5. Another big problem I struggled with is the oil flow from the back of the GM 4WD transmission. They have no seal in the back and the factory installed configuration keeps the oil between the GM TC and the GM adapter coupling. All that factory stuff is in the scrap pile now and is replaced with home-made parts which for various reasons will not hold the oil without puking it on the ground. I have designed, built and installed a blank off plate and seal that I hope will keep the oil out of the adapter coupling and off the ground. This is my second design for this part and I plan to test it tomorrow night. Transfer case is not installed yet, only blank off plate and adapter.


I know this is a lot to digest without pictures, will post tomorrow.

 

Keep at it mate. Don't give up.

 

Rear of transmission block off plate, used to control the oil from the back of the transmission. Sorry for the poor phone pictures, my grand kids have my tablet.

 

Summit shallow (car) oil pan.

 

Electric motor center differential lock setup.

 

What a goofy shaft. That thing will never work!

 

I used this piece from the back of the ZF transmission, but you could build your adapter coupling without it.

 

Adapter coupling.

 

I know what you're thinking, why not just divorce the TC and be done with it.
If you go that route you probably could use one of these. Also, be prepared to cut out a bunch of floor pan, lengthen parking brake cable, hi low shift cable, numerous wires and more. The front shaft will be extra long and the rear will be super short.

 

Everything reassembled with my newly designed oil block off plate and goofy transfer case connector shaft. Found the source of some vibration I was having, and made one new heavy duty mount for the transfer case.
Drove it through some deep ditches in 4 low and CDL engaged. No problems so far.... went about 25 miles today.