NP 205 Rebuild and Info

[79Betty]

Jbclassix. One helluva write up. When i tore mine apart it didn't have the spacer on the rear output. Now that i out it together the input from the tranny shaft slides back and forth. I've got it all torqued down but don't wantto put it in because when slid out it grinds horribly. When in farther it spins smooth as silk. Any ideas?
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[jbclassix]

Originally Posted by 79Betty

Jbclassix. One helluva write up. When i tore mine apart it didn't have the spacer on the rear output. Now that i out it together the input from the tranny shaft slides back and forth. I've got it all torqued down but don't wantto put it in because when slid out it grinds horribly. When in farther it spins smooth as silk. Any ideas?
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are you talking about the input shaft in the t-case or the coupler? If it is the input shaft for the t-case, the outer snap ring on the input bearing prevents the input from going back into the case, and the transmission-to-transfer-case adapter prevents the input from sliding forward, out of the case.

[79Betty]

Yes the input from tranny. So the "slop" iis supposed to be there?
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[jbclassix]

Originally Posted by 79Betty

Yes the input from tranny. So the "slop" iis supposed to be there?
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Yes. It is. On the spacer on the rear output, was your shoulder longer? Your speedo gear will be loose if it is supposed to have a spacer and doesn't.
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[79Betty]

I noteced it would move back on the sleeve. Could i just use a thick washer as a spacer?
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[jbclassix]

You will actually need that spacer. The yoke, spacer, and gear keep the output shaft riding on the bearings where they are supposed to. but let me triple check that. I have an output assembly I need to rip into anyway.

[jbclassix]

Newer case with a staked idler shaft on the rear side to prevent rotation.

['63GENIII]

Killer write up Jeremy! Thanks for the read. After reading this thread, I was able to completely disassemble, clean and reseal the divorced dodge 205 that is replacing the old T221 in my '63. It came out great.

[61K10]

63GENIII--does the dodge use the same mounting as the 221?

['63GENIII]

Originally Posted by 61K10

63GENIII--does the dodge use the same mounting as the 221?

Sent a PM. Didn't want to hijack but yes it fits
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[ElPasoCOunty]

Has anyone torn into their NP205 and found that the idler gear shaft only had one shim in it instead of 4?

I pulled mine apart this weekend and it only had one shim.

Thoughts?

'72 K20

[5ltretr]

Mine only had 2, some i have done had 3 or 4 and different thicknesses.

[woodsrat]

Just looked at the NP205 thread, What a great job on that!

I have a 1984 GMC 1 ton 4x4 transfer case stuck in low range or neutral.
Can move the low and neutral pin with a pry bar to chance them but Can't get the lever to go to 2 wheel or 4 high.

Now I am wondering if maybe the detent balls are out of place or if it has a broken spring in the one shaft that won't move, Any chance that can happen?

My linkage is defiantly different than that one in the pic. That looks like a nicer set-up.

[jbclassix]

Originally Posted by woodsrat

Just looked at the NP205 thread, What a great job on that!

I have a 1984 GMC 1 ton 4x4 transfer case stuck in low range or neutral.
Can move the low and neutral pin with a pry bar to chance them but Can't get the lever to go to 2 wheel or 4 high.

Now I am wondering if maybe the detent balls are out of place or if it has a broken spring in the one shaft that won't move, Any chance that can happen?

My linkage is defiantly different than that one in the pic. That looks like a nicer set-up.

I dont know what year GM started using the 4WD switch, but if yours has that, then I would check to make sure that isn't the culprit.

On the 205 you can also remove the PTO cover and gain easy access to your HI-LOW shift fork.

Both rods have to move to the NEUTRAL possition for the t-case to be in NEUTRAL. Does the LOWER one move at all, or only the upper?

[woodsrat]

Originally Posted by jbclassix

I dont know what year GM started using the 4WD switch, but if yours has that, then I would check to make sure that isn't the culprit.

On the 205 you can also remove the PTO cover and gain easy access to your 2HI-4HI shift fork.

Both rods have to move to the NEUTRAL possition for the t-case to be in NEUTRAL. Does the upper one move at all, or only the lower?

When you say PTO cover is that the cover straight out the rear of the transfer case?

The truck seems to go into 4 low and a neutral but the shifter just don't feel correct but it will move in 4 wheel low.
Upper rod I can move in and out with a bar but I can't get the bottom one to go either way.
Thanks

[jbclassix]

Originally Posted by woodsrat

When you say PTO cover is that the cover straight out the rear of the transfer case?

The truck seems to go into 4 low and a neutral but the shifter just don't feel correct but it will move in 4 wheel low.
Upper rod I can move in and out with a bar but I can't get the bottom one to go either way.
Thanks

Had to fix my thinking... the upper one (closest to transmission) is the hi-low, the lower one (closest to front drive shaft) is the 2-4

The PTO cover is the 6 bolt rectangular cover on the oposite side of the front output.

another suggestion is to jack up the front and rear end to take any torque off the drive line, then try shifting.

[woodsrat]

I did jack up the back end and tried that but not both ends, I will give that a try.

Looked last night and can't find any tags but it does look a lot like yours.
Did try to get my hands up on the top and can only feel one bolt for a detent ball, Is that possible.

Also, What do you mean by the GM 4wd shift, Mine does have the stick on the inside floor.

[jbclassix]

This is the switch I am talking about. I am researching to see what year GM started installing this in the t-case. It illuminates a 4WD indicator lamp on your gauges. This will be installed in in the plug for the lower detent ball.

[woodsrat]

Now I really need to get a better look but mine does have a thing that looks like that but I didn't see any wires hooked to it and I am pretty sure that it is in the highest plug on the transfer case.

Do the wires only work the dash lights?

[jbclassix]

Originally Posted by woodsrat

...Do the wires only work the dash lights?

Yes they do. I would really pull the PTO plate and have a look inside the case. That would give you a good idea of what direction to take.

[jjzepplin]

post some pics of the t-case and the inside.

[woodsrat]

Jacked up both ends of the truck and got it off of the ground and still can't move the lever inside.

Did take another look underneath and it has a lamp indicator plug like the picture in both of the detent holes and I can't find any wires for them.

[woodsrat]

Tried to get my son to get a few pics but they didn't work out very well.

I looked at the PTO plate and that is where the levers are for the dump box so I don't know what may come out of it if I take it off?

Any chance that you think that maybe the detent ball switch pin could be holding the shaft from going back in?
Still didn't find any wires that would go to it.

[jjzepplin]

You could try to remove both switches (I think there should only be one) and then try to move the lever. Both Have a Neutral so you have to find neutral before moving the other shaft. Make sense? Kinda like a manual trans.

[woodsrat]

So there should be a neutral on both shafts out of the transfer case?

So that tells me that maybe the lower shaft on the transfer case is maybe stuck in neutral since when I move the top shaft in or out with a pry bar the truck is either in neutral or low range.