np205 rebuild
 

Anyone ever rebuild a transfer case? I've got a good amount of slop. Was gonna do some junkyard shopping but I'd rather buy the kit and do the job in the winter if it isn't that bad.

never done it. but i think the rebuild kit is alot better than get parts from the junkyard

Ive got to pull mine to replace the seal in the adapter. Might rebuild it while its out. So far all I can find is IPBs. I'll put something up here if I find it.

If you need parts or kits try this : www.drivetrain.com

Enter np 205 in search or follow listing directions. They have a nice illustration and it looks like they have parts in addition to overhaul kits.

Jim

I've rebuilt two of 'em with the kits from drivetrain.com. ITs not bad at all, its really pretty easy. The critical part, or so I was told was setting the pre-load on the idler, which was done with shims. Nothing else really to it, except the dam shift rails. Once you figure out how to get those badboys out, its just like anything else, it comes apart one way, goes together the way you tore it down. The kit comes with extra gaskets that you won't use, but if you price buying the bearings and gaskets separately, its really a better buy to just bite the bullet and buy the entire kit from drivetrain.com. The folks there seem pretty knowledgeable about what's going on too. One oddball tool I had to get, and I can't remember what size socket it was, but the idler bolt(big bolt on the outside of the case) was some oddball thing, other than that it wasn't bad. Once you get the main output shaft out, and the front output shaft out, you need a little magnet to pull out a little pin from its hole, then you can pull the thrust bearing plate up and off. If you've never done one, you need to, good learning experience. The only bear I had with it, was the dam shift rails.
Just my thoughts on it.

I scanned an old article on rebuilding a 205 if you are interested in it, let me know.

If you can send the article to eric.post@libertymutual.com that would be great!

Here are links to the article.

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

and probably from some other article

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

I believe somebody sells a video, on this, as well...

never done it myself, might be on the agenda, tho...

-M