NP205 Transfer case Output shaft removal
 

Hello I am looking for ideas to help solve this issue.

I have watched and read about hitting the output shaft with a deadblow hammer to remove the shaft. I have whacked it with the DB hammar and with a brass pin and 4 lb hand sledge. Still won't move

HELP!

Re: NP205 Transfer case Output shaft removal
 

The rear output shaft: remove rear bearing housing from case, remove yoke, shaft slides out of housing.

The front output shaft: remove large aluminum cover on rear of case, remove front yoke, shaft comes out rear of case.

If either shaft does not come out easily it may be seized on the bearing, not usually a problem unless the case sat full of water or was run low on lube.

If you are removing the input shaft: remove the rear output shaft with the rear bearing housing, remove the snap ring from the shaft and drive the retaining pin out of the shift fork, shaft comes out rear of case.

Re: NP205 Transfer case Output shaft removal
 

Little adenum to that, remove yoke, remove 5 bolt aluminum bearing retainer, pry out bearing, remove speedo cable, unscrew speedo drive housing with gear, remove 8 bolts holding cast iron housing, break gasket seal on housing, gear will more than likely come out with housing while dropping individual pocket bearing rollers into bottom of case getting them stuck on factory magnet. Simple

Re: NP205 Transfer case Output shaft removal
 

You mentioned you've read about the process already, but just in case, here is the mother of all 205 rebuild threads - best I've ever read. May or may not help ya if it's seized.
http://67-72chevytrucks.com/vboard/s...d.php?t=469726