I assume you've got the SM465. Super granny low with no synchros. They always shifted kind of hard, as compared to others. No clashing, just takes some added effort. If your's clashes without double-clutching, you've got worn-out synchro rings. I used to think all HD truck transmissions were like that until I got my 92 Dodge diesel with the HD Gertag 5 speed. It shifts as smooth as glass.
As to gear oil in the 205 transfercases, I suspect it has more to do with it's design to hold thin oil and not leak. My 92 Dodge has the same 205 transfer case and it calls for 30W oil when driven below 32 degrees F and 50W when above. My 69 Power Wagon and my 79 Blazer also have the 205s, but they call for heavier oil. So, same internal parts, but thinner oil called for in the newer ones.
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