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So what should I run in my manual tranny and 205? Ive seen some GM synthetic stuff, and ran it in my 2wd tranny without issue should I try this or should I just do the 90W thing?

Anyone ever make there own hydro clutch line? Chevy dealer gets 70 bucks for the line I need and Im not even interested in payin that for one. Are the ends on that similar/same as brake lines?
 

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For the 205, my repro '71 IH Truck Service Manual for my TravelAll w/205 (divorced) states:

"Special Lubrication requirements:

Fill the transfer case with SAE-75 straight mineral oil where unit is subjected to temperatures consistently below 0ºF or where parked vehicles are exposed to unusual cold for long periods. Where temperatures are consistently above 90ºF (unusually hot), fill case with SAE-140 straight mineral oil."

Better oils are offered now. I throw in Redline's MT90 that is like mineral oil. Works good in my manual trans, too, because Redline designed it to work right with the synchronizers. Not too slippy, not too thick. The "MT" stands for Manual Trans. Can't say if it's any better than other synthetics.
 

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I use Synthetic, but only because I do alot of water crossings and the synthetic will not break down as bad if water made it's way into my case. if your not worried about water then I would'nt bother with the synthetic.
The hydro clutch line, I have seen people make them up from break lines with the proper double flaring tool before, but I don't recommend it as the steel line does'nt like the constant flexing that it will receive offroad. You might be able to get a good flexable one made for less than $70 at a hydralics shop. Mine cost me about $35 and is twice as heavy as the OEM one.
 
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