Ok, its been 3 years, time to update. The flange issue has been fixed. My 205 doesnt leak. I put the speedi sleeve over the brand new flange and it stopped the leaks.
It sounds like some people make the correct sized yokes and others dont? I heard of some others having this same issue and when I gave them the speedi sleeve part # it fixed their issue too. Anyways, problem is fixed. speedi sleeve part # is 99210 for anyone with the same issue.
Shifting is fixed, there is a technique to shifting a 205 IMO, strong arming them is not the answer if you have cable shifters, if you shift from reverse to drive, there is a split section load is let off the gears and you can shift it and it goes in and out of gear with ease. No more complaints there.
mpg hit is still there, then I threw 43s on it a year after the 205 and that made mpg worse
I am about to do redo my rear suspension and I hope to solve my range with more fuel capacity. I dont care about mpg, I care about range for remote driving on the highway.
Not related to the 205 but I will state some had issues with the NWF blackbox overheating, my OG behemoth box has done a 1000 mile trip in 100+ degree heat and had no issues and did a 1700 mile trip in sub freezing temps and had no issues. Magnum boxes have tens of thousands of UA road miles with no overheating issues. NWF supposedly fixed their issues with a new scalloped design in the case to allow more fluid capacity. I do wonder if it aerates the fluid but it seems to have fixed their issues.
So long story short, 3 years later, I am happy with my big dumb, heavy, 205 doubler that is stout and takes abuse.