Best NP 205 Rebuild Kits?

[rowdy11]

Anyone have any recommendations on a good Rebuild Kit for the 205? Going to be modifying mine to fit with a 6L90E (meaning an adapter kit) and I wanted to rebuild the whole thing while I have it apart.

[sweetk30]

most are about the same anymore .

look for solid roller / all roller needle cage bearings over the spaced out ones with the little cage that holds them apart .

there is a lot of good write up's on here just above this post and other sites . i did one years ago with tons of pics on www.ck5.com in the advanced section .

good time to beef up to a 32 spline front if you plan on bit power and play time . otherwise a 30 spline is good over the small 10 spline .

[rowdy11]

Thanks Sweet! I will dig in and take a look. Good call on the 32 spline. I have to beef up to the 32 spline to mate to the 6L90 anyway, but I do plan about 400ish HP from my LS engine so it’s sn excellent idea.
My 205 case was mates to the TH 350 so I have the smaller bore up front. I’m debating whether it will be cheaper to have a machine shop bore it out or just buy another empty 205 case with the big bore when I rebuild it.

[Bad4wd]

I get most of my parts from this guys. There in Redding CA.
https://transpartswarehouse.com/
You can find there stuff on ebay to. Dave...

[sweetk30]

just punch yours from 80mm to 90mm bearing hole size if i recall . stupid easy to do for any machinest guy .

i have a stock pile of cases i will be punching out here soon to sell as big bearing size .

[Orange Crate]

It depends on what you want. If you want to never rebuild that gearbox again you might want to get the best bearings available. I would look for US made bearings or Japan. Seals are a crap shoot and you'll probably have to change them out anyway if you use the 205 a lot.

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

[Highcountrybulls]

I’m also updating my truck to LS and a 6L80 powertrain, The 205 case is at the machine shop now getting the input bearing bore punched out for the new larger shaft. I had planned to replace all the bearings until I tore it down and everything in it looked like new so I just ordered a seal/gasket kit and will be reusing all the bearings that were in it originally. Mine won’t be wheeled hard so I’m staying stock with the front output.

[rowdy11]

Thanks for the responses everyone and for the helpful links. I found a small machinist who will bore out the case from 80-90 MM for 30 bucks. Not bad.

I think I'm going to get in and see if the bearings need replacing (expect so) and then order that and seals etc from there. I hope I'm in the same boat as you highcountry...but I expect I'll need to replace bearings and I've already got my eye on something from offroaddesign.

By the way, what adapter kit are you using for your 205 to 6L80? Also, do you have a transmission brace figured out yet? The trans brace isn't something I've found to be pre-fabbed and for sale because the 6L's are still so rare compared to the 4L80 swaps.

[sweetk30]

if the fluid is clean and not water then the bearings will prob be o.k. . only time i need bearings is super high miles and or major water mix run for a long time .

check your fork pads were they ride on the lock ring and the 45* teeth for the lock ring . if worn then call up offroad design they sell new .

[Highcountrybulls]

Originally Posted by rowdy11

Thanks for the responses everyone and for the helpful links. I found a small machinist who will bore out the case from 80-90 MM for 30 bucks. Not bad.

I think I'm going to get in and see if the bearings need replacing (expect so) and then order that and seals etc from there. I hope I'm in the same boat as you highcountry...but I expect I'll need to replace bearings and I've already got my eye on something from offroaddesign.

By the way, what adapter kit are you using for your 205 to 6L80? Also, do you have a transmission brace figured out yet? The trans brace isn't something I've found to be pre-fabbed and for sale because the 6L's are still so rare compared to the 4L80 swaps.

Man I wish I could get my case machined for $30! It's costing me about $125 up here but everything is high priced in AK.
I went with the Advance Adapters kit as it seemed like the most comprehensive way to go (but you pay for it). I'm hoping to reuse my original trans/t-case crossmember and adapt that to the AA mounting points. If that doesn't work I'll fab one up from rectangle or dom tube.

[sweetk30]

3/4 down the page gu4093 kit for fig 8 case or just above it gu4092 for round 6 case . http://offroaddesign.com/catalog/NP205%20Parts.htm