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Old 04-05-2021, 09:43 PM   #1
K20-Bowtie
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NP205 Install Tips

SM465 & NP205 on 72 K20 - leaking from many points. Decided to yank both out (pic attached).

A buddy of mine helped me reinstall a rebuilt SM465 - took some finesse to line up transmission shaft, but it's in and bolted down.

In the process of cleaning up NP205 and replacing seals. Any tips on reinstalling transfer case by myself? Have a transmission jack.
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Old 04-05-2021, 10:01 PM   #2
kwmech
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Re: NP205 Install Tips

Get a couple of double ended studs and place them across from one another where putting a nut on the adapter is accessible. I used to bench press them, but I'm getting too old for that sh.. (with the 205 weighing in at 156#)anymore. Make/weld up a plate that will bolt to the jack and bolt to the t-case at the approximate angle.
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Old 04-06-2021, 08:51 AM   #3
jaros44sr
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Re: NP205 Install Tips

I used exhaust manifold studs, they have a small hex head to put a wrench on , helps alignment, also i put the crossmeber on, helps to stabilize the 205 on the trans jack
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Old 04-06-2021, 06:19 PM   #4
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Re: NP205 Install Tips

I built a flat plate with flat bar welded to it.
I could bolt the flat plate to the jack.
The flat bar has holes in it that match some on the transfer-case.
That way I could tilt it with out worrying if it going anywhere.
The are heavy and very dangerous if you drop it.

If I remember correctly the speedometer output doesn't even have a seal on it.
Things have changed since the 70's! Some things are even better.

A friend called me today wondering what do do as an acquaintance broke the case of his manual 5 speed and dropped the transfer-case to the ground. Oh to be young again out stump humping. LOL.
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Old 04-06-2021, 09:32 PM   #5
72Cheyenne454
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Re: NP205 Install Tips

After years of manhandling NP205's into position, I finally built a jig that fits into my floor jack. Makes it so much easier. Unfortunately, I just had to use it, as my transfer case adapter seals were leaking and I was getting ATF in the tcase.

Miles
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Old 04-06-2021, 09:46 PM   #6
DeadheadNM
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Re: NP205 Install Tips

Good time to replace the speedometer seal and adapter nut O-ring. Torque King sells both (there are two seal sizes): https://torqueking.com/product/30065...ransfer-cases/

I just changed these out on my Blazer and no more leak.
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Old 04-06-2021, 10:53 PM   #7
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Re: NP205 Install Tips

Quote:
Originally Posted by 72Cheyenne454 View Post
After years of manhandling NP205's into position, I finally built a jig that fits into my floor jack. Makes it so much easier. Unfortunately, I just had to use it, as my transfer case adapter seals were leaking and I was getting ATF in the tcase.

Miles
Love that jig that is pretty sweet. They suck to put in by yourself with no jack. Ive bench pressed a few of them. Is that an old school harbor freight floor jack? My dad had one just like that for a long time, he said it was from the late 80s.
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Old 04-06-2021, 11:34 PM   #8
72Cheyenne454
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Re: NP205 Install Tips

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Originally Posted by 57taskforce View Post
Love that jig that is pretty sweet. They suck to put in by yourself with no jack. Ive bench pressed a few of them. Is that an old school harbor freight floor jack? My dad had one just like that for a long time, he said it was from the late 80s.
I recently inherited that floor jack from my father. I was in high school when dad bought that jack, so it must have been back in the late 80's... wow, time flies. Not sure where it came from, but it has been a bullet proof jack.
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Old 04-06-2021, 11:44 PM   #9
57taskforce
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Re: NP205 Install Tips

LOL yea my dad had his when I was a kid in the late 80’s-early 90’s all the way up till about 5 years ago. Lived it’s whole life in gravel haha. When he finally killed it off, It was almost like the loss of a family heir loom
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Old 04-07-2021, 12:36 AM   #10
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Re: NP205 Install Tips

I feel obligated to point out that a transmission jack is the right tool here.. standard floor jacks are not designed to carry loads out from under vehicles.. they can get caught and fall over or simply tip over from unbalanced weight resulting in serious injury..

trans jacks are wider, have adjustable legs on a wide platform that can be tilted both ways, safety chains to keep trans from falling off, and all four wheels swivel so it can be easily maneuvered any direction to minimize pushing it over..

now that's out of the way, I'll admit I've muscled my fair share of trans with floor jacks, even on dirt and gravel.. bench pressed auto trans in and out with no jack at all.. but just lucky like most that have gotten away with it so I wouldn't advise it when better options are available..

trans jacks with properly adjusted supports or custom adapters will make the job much easier and much safer.. and likely faster with less hassle aligning everything..

good luck!
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Old 04-09-2021, 05:13 AM   #11
Richard
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Re: NP205 Install Tips

Having removed and installed a 205 t-case several times. I will note that a transmission jack makes it no easier without some kind of jig.
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