Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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?

Re: NP 205 Rebuild and Info
 

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

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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.

http://up.picr.de/3473051.jpg

Re: NP 205 Rebuild and Info
 

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?

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

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.

Re: NP 205 Rebuild and Info
 

Do you have the linkage between the two rods? There are interlock pins between the rods, they prevent the rods from moving out of sync from each other. If you are in 4-Low, then both rods should move out at the same time to NEUTRAL. then the top rod should move out one more time to 2-HI, then the bottom rod should move out one more time to 4-HI.

If you are trying to get the top rod into 2-HI with the bottom rod in 4-LOW then it will not go because of the interlock pins.

Re: NP 205 Rebuild and Info
 

https://www.youtube.com/watch?v=qUGA...t6-t1kzFOoWHcg

Here is a really crappy video... but after an hour trying to upload to the new youtube... I'm not doing another one

http://youtu.be/qUGAHCMjHiA

Re: NP 205 Rebuild and Info
 

I'm looking for a adaptor for a np 205 to a granny 4 spd ona a 71 any body no of one for sale? Need one before cursing the coast.

Re: NP 205 Rebuild and Info
 

Video looks good on this end!

Yes I do have the linkage between the two rods.
Each one is in each side and there is a single rod between the two in the center to the shifter linkage.
Does that sound correct?

Maybe I should remove the front driveshaft then try to disconnect the linkage and try to move it the way that you did in the video?

Thanks for being patient with me.

Re: NP 205 Rebuild and Info
 

Had some more time again so I went back under this thing again.
Removed the front drive shaft to get into the shafts a little better then removed the lower detent switch (spring and ball) and still can't move the shaft at all.

Shift bar and linkage look different on mine, Hook is on the lower shaft and cross over plate is a pin type linkage on mine.
What should I try now?

Re: NP 205 Rebuild and Info
 

Brother-we are going to need some pics if we are going to get this thing fixed for you.

Re: NP 205 Rebuild and Info
 

Ok, Since the drive shaft is now off I will try to get some better pics this weekend to see what you guys think.
May need to send someone the pics since I don't know how to post them.

Re: NP 205 Rebuild and Info
 

You should start your own thread about the issue and PM us the link if you want. You will get more of us looking at it and more suggestions.
We kinda hi-jacked this thread. Just sayin.

Re: NP 205 Rebuild and Info
 

Started a new one in this section and also brought the one in 1973-1987 Chevy & GMC message board back to the top from last month.
Thanks for any help and I will try to get pics this weekend.

Re: NP 205 Rebuild and Info
 

That's my next project since I also have the T221. Ready for it to byebye after I get new gears the rear and front end. Good details, right on the money

Re: NP 205 Rebuild and Info
 

Are there supposed to be any o rings or seals on the speedometer output shaft and retaining nut?

My 72 case was leaking bad out of the speedo cable and when I removed the nut and shaft there were remnants of two rubber o rings. PO intall or factory? Part numbers or o ring sizes?

Thanks

Re: NP 205 Rebuild and Info
 

YES
Mine to and no idea on part number or size

Re: NP 205 Rebuild and Info
 

This was super helpful thanks!

Re: NP 205 Rebuild and Info
 

This looks like an excellent guide to rebuilding your NP205. The only thing I might do differently is, wait till you get the entire thing back together, then mask off the little stuff, then paint it, thereby protecting everything including the hardware and covers.

Re: NP 205 Rebuild and Info
 

Great info!! Just a couple of questions:
Are you suppose to apply rtv to any of the gaskets?
Does anyone have the correct needle bearing counts for each bearing?

Re: NP 205 Rebuild and Info
 

subscribed

Re: NP 205 Rebuild and Info
 

Delete if not allowed

Not sure if I can post this here but this is the place to buy master kits for the NP205

http://www.quad4x4.com/catalog/#chevy_gmc

Re: NP 205 Rebuild and Info
 

sure is the place if you want to get taken for a ride . . . .

$419.xx bucks for a master gasket / bearing kit for a np205 large bearing. :barf:

and I have never been a fan of web sites making you click the link to go to another page to see the prices .

Re: NP 205 Rebuild and Info
 

That place sucks.

ORD has rebuild kits for about $200.

http://offroaddesign.com/catalog/NP2...e_Rebuild_Kits

Re: NP 205 Rebuild and Info
 

oh ya I know ord . . . I should have stock in them .

and ever since the guy purchased the site linked above he has go crazy in prices and changing the site all around.

and ord is were I get lots of my stuff . but even some of there prices are high .

some things I get from evilbay . . .

Re: NP 205 Rebuild and Info
 

Outstanding write up. It's greatly appreciated. Cheers, Jack

Re: NP 205 Rebuild and Info
 

Killer write up! Thank you!!!

Re: NP 205 Rebuild and Info
 

Just curious, how many needle bearings were there on the rear of the front output shaft?

Re: NP 205 Rebuild and Info
 

depends on if older FULL needle bearing cup or newer style partial with cage .

if older full setup there should be no space left for another bearing needle .

Re: NP 205 Rebuild and Info
 

Hello all, I just wanted to get a sanity check on what I'm seeing. On the rear output shaft, the rear end where the needle bearings get installed, in I'm seeing vertical stripes. I don't know if this is wear or if they were machined in and are supposed to be there. They look really clean and almost intentional. Also, what helps to complicate things is that I apparently have a weirdo metal drive speedo unit. I removed the snap ring and washer for clarity. I can't find any clear pictures on the internet of what it's supposed to look like. Thanks for your help!

Attachment 2082182

Attachment 2082184

Attachment 2082183

Re: NP 205 Rebuild and Info
 

Those lines are not supposed to be there

Re: NP 205 Rebuild and Info
 

I didn’t have any indentations when I replaced my needle bearings. I’ll try to find a picture.