Re: NP 205 Rebuild and Info
 

The 205 is one of the easiest things ive ever done on an r&r. I have done, nearing 15 of em id say, for people afraid of em. Its just parts. Same thing with a th400. Take it apart. See whats inside. Youd be amazed at the simplicity.
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Re: NP 205 Rebuild and Info
 

On this one that I built there is an o-ring on the input shaft of the t-case that seals to the inside of the adapter sleeve, and there is a plain encased seal in the adapter housing that seals to the outside of the adapter sleeve. I am going to finish rebuilding the t-case soon.

Re: NP 205 Rebuild and Info
 

Sounds good guys, thanks for the help

Re: NP 205 Rebuild and Info
 

Wow. 2 years later...

Tips for the Yokes. I sleeved both. I use green lock-tite on them to prevent seepage between the parts. i apply RTV sealant to the inside of the yokes, and not the shaft. This way you will not be pushing RTV into the case.
10 spline front yoke repair sleeve part number (federal mogul 99174)
32 spline rear yoke repair sleeve part number (federal mogul 99212)

https://lh6.googleusercontent.com/-J...192729_664.jpg

Spline washer seal. important piece. Only works on the 32 spline yokes in my opinion.

https://lh4.googleusercontent.com/-8...192952_812.jpg

Torque for the rear yoke is 150lbft.

repeat steps for the front yoke. The front has a dust shield.

https://lh5.googleusercontent.com/-P...200529_112.jpg

https://lh3.googleusercontent.com/-t...200548_740.jpg

https://lh4.googleusercontent.com/-y...200620_344.jpg

I will show pictures of the early style adapter for reference.

Re: NP 205 Rebuild and Info
 

Do you happen to have any pics of the adapter seals? Mine is the o ring style on the trans to adaptor and idea on the case to adaptor seal? My trans was leaking atf into the t case so here I am..

Re: NP 205 Rebuild and Info
 

Auto Zone had mine in stock. They look just like wheel seals and the coupler just sits centered on them. They seal the outer part of the coupler while the inner is sealed by the "o" ring. Case to adapter gasket can be bought on ebay for a couple bucks.

Re: NP 205 Rebuild and Info
 

http://i29.photobucket.com/albums/c2...ps9891e9e7.jpg
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Re: NP 205 Rebuild and Info
 

Those are the three seals you will need. Small oring is for the inside of the coupler. Big oring is for the trans to adapter. Regular lipped seal is outside of coupler.
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Re: NP 205 Rebuild and Info
 

I found all the seals with the exception of the small o Ring seal to the shaft
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Re: NP 205 Rebuild and Info
 

Comes in my gm 205 gasket kits.
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Re: NP 205 Rebuild and Info
 

I have 2 lip seals in my adapter. The larger one obijuan doesnt have pictured i cannot find a PN for. For autos i recommend putting some silicone on the inside of the coupler like i did the yokes.
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Re: NP 205 Rebuild and Info
 

Here is what I have for seals.

there are 2 lip seals inside the 1st gen adapter.

here are the 2 lip seals.

transmission side
https://lh6.googleusercontent.com/-_...162009_948.jpg

transfer side
https://lh5.googleusercontent.com/-r...162018_629.jpg

here you can see where the 2 lip seals ride on the coupler
https://lh3.googleusercontent.com/-_...162110_565.jpg

here you can see the sealing surface the o-ring on the t-case input shaft seals against. Make sure this side of the coupler is on the t-case side. Also, clean the splines on the coupler, and put some silicone on it. This will act as a back-up to the o-ring.
https://lh6.googleusercontent.com/-V...162103_185.jpg

Re: NP 205 Rebuild and Info
 

Thanks for the added information, should come in handy....

Re: NP 205 Rebuild and Info
 

Bad image of 32 spline front output shaft

https://lh5.googleusercontent.com/-B...212236_533.jpg

Re: NP 205 Rebuild and Info
 

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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Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

Yes the input from tranny. So the "slop" iis supposed to be there?
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Re: NP 205 Rebuild and Info
 

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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Re: NP 205 Rebuild and Info
 

I noteced it would move back on the sleeve. Could i just use a thick washer as a spacer?
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Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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

https://lh3.googleusercontent.com/-H...155202_460.jpg

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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

Re: NP 205 Rebuild and Info
 

Sent a PM. Didn't want to hijack but yes it fits
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Re: NP 205 Rebuild and Info
 

Do you have a part number for the larger seal needed for the front output after you put the speedy sleeve on ? I have the 30 spline output shaft and yoke, but I am guessing that the outside diameter is the same as your 10 spline ? How long should I let the silicone sit on the inside of the yoke before I put it on the shaft? Nice write up and very helpful. Thanks