NP205 rebuild - The 1947 - Present Chevrolet & GMC Truck Message Board Network

cheyenne10 · 11-21-2002, 11:43 AM

I'm thinking about getting a T350 trans and NP205 transfercase rebuilt along with tranny adapter. Which parts of this are do-able by limited knowledge truck owner (if any) and what is involved? Is there a manual on transfercase rebuilds? Has anyone bought these parts rebuilt online (out of town) and had shipped? What should these things cost? I want a strong reliable setup for K20 with stock motor, nothing too fancy.

landon4421 · 11-21-2002, 07:13 PM

Hello how is it going ? Anyway I bought a rebuild kit for my np205, it was about $150.00. I had my friend do the rebuild for me. He works for a chevy dealership. I would advice you to go to your local chevy dealer and ask the parts department if they can get you a book to do the rebuild, or mabe they will let you make copys of the book. Back to the ? about is it dueable, everything is dueable. My buddy that rebuilt my t-case said it was rather easy, but he works on cars all day long. So I would also see the man at the chevy dealership that works on the transmissions and ask him if he would like a side job you buy the parts he dose the work. Thats my two cents on you ? good luck !!

**Yukon Jack** · 11-22-2002, 12:29 PM

Here is some info on rebuilding an NP205

http://www.j0ker.org/~yukon/misc/np2...5rebuild-1.jpg

http://www.j0ker.org/~yukon/misc/np2...rebuild-01.jpg

http://www.j0ker.org/~yukon/misc/np2...rebuild-02.jpg

http://www.j0ker.org/~yukon/misc/np2...rebuild-03.jpg

http://www.j0ker.org/~yukon/misc/np2...rebuild-04.jpg

Hope that helps.

cheyenne10 · 11-23-2002, 06:52 PM

That is a good article. I am unexperieinced on T-cases. Does anyone have other sources for info. on doing this yourself? I want to gather as much info. as I can. I like the No-special tools option. Where can I get a bearing driver as mentioned in above article? It is used to "tap the new races into place on the intermediate Bearing gear".

cheyenne10 · 12-04-2002, 08:24 PM

Looking for more details. Is there such thing as a rebuild manual for one of these?

*MJF* · 12-04-2002, 08:45 PM

Yukon Jack, Thanks for posting that. I will be replacing my output shaft soon & was considering doing the full rebuild. At least now I can read through that & see if I think I can do it.

Mike

My72Cheyenne · 12-24-2002, 02:45 PM

I just rebuilt my 205. I wouldn't recommend getting parts at GM unless you have extra cash to throw around. They are brutal! I was able to find parts through parts houses. The only problem you may have is the output bearings (needle style) have been discontinued so you'll have to switch to a newer style that has a needle retainer built into it. From an assembly point of view, the bearing is better, but it didn't fit as nicely as the original. But there is no other option. Other than that, FOLLOW THE INSTRUCTIONS and you'll be fine. Good luck

Popeye · 12-24-2002, 03:24 PM

If you have not already noticed, that np205 case is a heavy SOB. I droppped mine durring an install and was lucky I didnt crush my head. Best of all nothing broke except the concrete it hit. I recomend a good floor jack and a second set of hands to help pull it and install it. If you gotta use GM for parts, pack your wallet with extra cash. These guys were able to find me parts for the 205, http://www.4wheelparts.com

Good Luck

OLDCHEV4X4 · 12-28-2002, 02:24 PM

i got all my parts from 4xheaven in Gloversville NY. 800-800-1679.
Tell em Randy from Pennsylvania sent you.
The factory overhaul manual is a very good guide and has lots of pictures. All the parts guys sell them.
Randy

MAC67 · 01-27-2003, 01:28 AM

the 205 is pretty dang easy to rebuild,,the front drive shaft out put is removed by dropping the front youke or plate from the shaft ,,then remove the rear plate,,it is held on by about 10 bolts then that shaft will slip right out the back,,,when you go to remove the tranny input and rear driveshafdt output,,be careful,,,there are about 10 fairly decent sized needle bearings where the input shaft rides in side the rear output,,give em a good coat of grease when you slip em back together so they dont fall out,,you gotta really fish the shifter fork collar around to get it to line up,,and once you get the rear shaft slid back in be sure to line youre shifting gear on the fork up so it will still shift or when you tighten it youll pinch it and nothing will turn,,hope this helps a little

outlaw · 01-27-2003, 02:08 AM

I don't know about where you live but where I live there is a 4x4 shop and he can hook me up with any part that I want at pretty realonable rates and will rebuild it if wanted but as far as a manual I would ask around and see if anyone you know has a Chiltons manual go by and ask someone at a mechanic shop and tell them what you got and what you are doing and most will help you any way that they can good luck

11-21-2002, 11:43 AM	#1
cheyenne10 Senior Member Join Date: Apr 2000 Location: Oregon Posts: 2,511	NP205 rebuild I'm thinking about getting a T350 trans and NP205 transfercase rebuilt along with tranny adapter. Which parts of this are do-able by limited knowledge truck owner (if any) and what is involved? Is there a manual on transfercase rebuilds? Has anyone bought these parts rebuilt online (out of town) and had shipped? What should these things cost? I want a strong reliable setup for K20 with stock motor, nothing too fancy. __________________ Bob

11-21-2002, 07:13 PM	#2
landon4421 Life is Good ! Join Date: Mar 2002 Location: Hollister, Ca. Posts: 1,992	Hello how is it going ? Anyway I bought a rebuild kit for my np205, it was about $150.00. I had my friend do the rebuild for me. He works for a chevy dealership. I would advice you to go to your local chevy dealer and ask the parts department if they can get you a book to do the rebuild, or mabe they will let you make copys of the book. Back to the ? about is it dueable, everything is dueable. My buddy that rebuilt my t-case said it was rather easy, but he works on cars all day long. So I would also see the man at the chevy dealership that works on the transmissions and ask him if he would like a side job you buy the parts he dose the work. Thats my two cents on you ? good luck !! __________________ '72 Chevy C10 4x4 shortbed "Project" '71 Chevy C10 2wd longbed "partsrunner" '91 Chevy Burb 4x4 "kidrunner" '14 Honda Accord Sport "commuter"

11-22-2002, 12:29 PM	#3
Yukon Jack Post Whore Join Date: Feb 2000 Location: Rose Hill, KS, USA Posts: 12,683	Here is some info on rebuilding an NP205 http://www.j0ker.org/~yukon/misc/np2...5rebuild-1.jpg http://www.j0ker.org/~yukon/misc/np2...rebuild-01.jpg http://www.j0ker.org/~yukon/misc/np2...rebuild-02.jpg http://www.j0ker.org/~yukon/misc/np2...rebuild-03.jpg http://www.j0ker.org/~yukon/misc/np2...rebuild-04.jpg Hope that helps. __________________ 1970 Blazer with a 400 sbc and 4" lift 1980 Pontiac Trans Am, 455 Oldsmobile 2012 Kawasaki Concours 14

11-23-2002, 06:52 PM	#4
cheyenne10 Senior Member Join Date: Apr 2000 Location: Oregon Posts: 2,511	Yukon Jack That is a good article. I am unexperieinced on T-cases. Does anyone have other sources for info. on doing this yourself? I want to gather as much info. as I can. I like the No-special tools option. Where can I get a bearing driver as mentioned in above article? It is used to "tap the new races into place on the intermediate Bearing gear". __________________ Bob

12-04-2002, 08:24 PM	#5
cheyenne10 Senior Member Join Date: Apr 2000 Location: Oregon Posts: 2,511	TTT Looking for more details. Is there such thing as a rebuild manual for one of these? __________________ Bob

12-04-2002, 08:45 PM	#6
MJF No longer truckless Join Date: Mar 2002 Location: Campbell, CA Posts: 299	Yukon Jack, Thanks for posting that. I will be replacing my output shaft soon & was considering doing the full rebuild. At least now I can read through that & see if I think I can do it. Mike

12-24-2002, 02:45 PM	#7
My72Cheyenne "Work in Progress" Join Date: Dec 2002 Location: Bend, Oregon Posts: 55	I just rebuilt my 205. I wouldn't recommend getting parts at GM unless you have extra cash to throw around. They are brutal! I was able to find parts through parts houses. The only problem you may have is the output bearings (needle style) have been discontinued so you'll have to switch to a newer style that has a needle retainer built into it. From an assembly point of view, the bearing is better, but it didn't fit as nicely as the original. But there is no other option. Other than that, FOLLOW THE INSTRUCTIONS and you'll be fine. Good luck __________________ 72 Cheyenne 4x4, 350, th350, np205, factory air, tach, headliner, tilt

12-24-2002, 03:24 PM	#8
Popeye Registered User Join Date: Dec 2002 Posts: 2	If you have not already noticed, that np205 case is a heavy SOB. I droppped mine durring an install and was lucky I didnt crush my head. Best of all nothing broke except the concrete it hit. I recomend a good floor jack and a second set of hands to help pull it and install it. If you gotta use GM for parts, pack your wallet with extra cash. These guys were able to find me parts for the 205, http://www.4wheelparts.com Good Luck

12-28-2002, 02:24 PM	#9
OLDCHEV4X4 Registered User Join Date: Apr 2000 Location: Chester County PA, USA Posts: 1,228	i got all my parts from 4xheaven in Gloversville NY. 800-800-1679. Tell em Randy from Pennsylvania sent you. The factory overhaul manual is a very good guide and has lots of pictures. All the parts guys sell them. Randy __________________ 72 k/10 short wideside 72 k/5 Blazer 72 K/5 Blazer - obstacle course racer 72 custom/10 8' bed 70 K/5 Blazer 67 C-30 GMC Flat bed 86 GMC K2500 Plow Truck 85 GMC K3500 84 M1008 85 M1008 77 G30 Motor Home 72 Sears 12hp Tractor Glenmoore, Pennsylvania

01-27-2003, 01:28 AM	#10
MAC67 " SHOW ME" Join Date: Jan 2003 Location: shelbyville illinois Posts: 2,624	the 205 is pretty dang easy to rebuild,,the front drive shaft out put is removed by dropping the front youke or plate from the shaft ,,then remove the rear plate,,it is held on by about 10 bolts then that shaft will slip right out the back,,,when you go to remove the tranny input and rear driveshafdt output,,be careful,,,there are about 10 fairly decent sized needle bearings where the input shaft rides in side the rear output,,give em a good coat of grease when you slip em back together so they dont fall out,,you gotta really fish the shifter fork collar around to get it to line up,,and once you get the rear shaft slid back in be sure to line youre shifting gear on the fork up so it will still shift or when you tighten it youll pinch it and nothing will turn,,hope this helps a little

01-27-2003, 02:08 AM	#11
outlaw Registered User Join Date: Dec 2002 Location: Leesville, Louisiana Posts: 80	I don't know about where you live but where I live there is a 4x4 shop and he can hook me up with any part that I want at pretty realonable rates and will rebuild it if wanted but as far as a manual I would ask around and see if anyone you know has a Chiltons manual go by and ask someone at a mechanic shop and tell them what you got and what you are doing and most will help you any way that they can good luck



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