Re: NP 205 Rebuild and Info
 

Thanks a ton, i will be using this this winter when i do a sm465 and np205 rebuild!! Invaluable!

Re: NP 205 Rebuild and Info
 

Awesome thread, thank you!

Re: NP 205 Rebuild and Info
 

I'm glad that everyone appreciates this thread! I guess I should let everyone know why I haven't installed the yokes and adapter yet. Some of you may know that in September I was in an accident during my move from Colorado to California. Unfortunately I was unable to tow the trailer with all my stuff in it the rest of the way, so the trailer, and everything in it, are in storage in Colorado. The t-case, the suburban it goes in, all my shop tools, everything.

Hopefully I will get out to CO this year and finish this up for all you!

Re: NP 205 Rebuild and Info
 

since the 205 is super common and this is a good resource ill add what i know to be true. please feel free to add your input.
keeping this to 69-72, 73-87/91 big body pickups


ALL crew cabs were fixed yoke.
regular cabs with carrier bearing were fixed yoke.
post 1985 np205 regular cabs are slip yoke.
all 1980 tcases were 205s. most slip yokes.
all rear output shafts are 32 spline. fixed and slip.
both slip and fixed yoke can be swapped with just removing the 8 bolt housing and removing as an assembly. also between chevy ford dodge and international. speedo and breathers just change.
vss introduced in 1990.
all 205s were figure 8 front pattern until 1985.
1985 introduced the round pattern 205.
i think 73 the speedo cable moved to passenger side.
several assortments of shifter styles.
1985 also introduced the W and S crossmembers to be used with short adapters and one piece rubber mounts.
pre 1985 one ton 205s had a flatter crossmember than 1/2 and 3/4 tons.
pre 1985 1 ton crossmembers went INSIDE the rails.
pre 1985 1/2 and 3/4 tons went below the rails.



the common/early sm465 version of the 205:
figure 8 pattern face
ten spline input male
small input bearing
ten spline front output if it has the spicer CV.
30 spline front output for the later flanged cv front driveshaft.
uses the taller two footed adapter

the other/later sm465 version of the 205
found post 1985
round pattern face
32 spline female input gear. with the BIG bearing case.
LONG input gear, around 4". not short th400 style.
30 spline front output flanged
uses the short foot adapter with one piece rubber mount


th350 version
27 spline male input gear.
small input bearing
figure 8 pattern only offered.
tall adapter.
can be used to put behind a 700r4.


early th400 version
figure 8 pattern face
32 spline short input gear, 2" ish.
large input bearing
strongest for offroad applications especially doublers


later th400 version
found 1985 and newer
round pattern face
long input gear same as later 465 version.
same large input bearing
30 spline flanged front output.
this is what you want for putting it behind an nv4500.
use a pre 1985 short th400 input gear if you dont want to use the advance adapter spacer. but thats a whole nother can of monkeys.

4l80 version
1991 only
round pattern face
large input bearing
does not share same adapter as th400.
has its very own adapter
same long input gear
VSS


ford international and dodge np205
they have a 32 spline front output shaft
these all swap over to GM cases to enable larger/better yokes to be installed.

Re: NP 205 Rebuild and Info
 

The holy grail of NP205 information!

Re: NP 205 Rebuild and Info
 

Thank you, and thank you obijuan for your contributions.

I will be adding more info as time goes on. Please do the same!

Re: NP 205 Rebuild and Info
 

Is there any info. on the seals and how they are installed for the adapter that bolts to the trans? Seems this is where mine is leaking

Help?

Thanks for taking the time jbclassix

Re: NP 205 Rebuild and Info
 

On the transmission side of the adapter there is a groove for a rubber o ring.
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Re: NP 205 Rebuild and Info
 

There are also two regular type seals that are in the adapter for the coupler outer seals. The inner is the o ring. This keeps fluid from your trans from going into your t-case.

Re: NP 205 Rebuild and Info
 

its been a while...but this is a super quality thread...lots of work went into it!

I am not exctly up to par on the level required to do this...but I just got a rebuild kit for my local shop that is familiar with such.

it was very informative to actually see whats going on...

I can do most on my 67 CST...but we all have our limitations...;)

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

Re: NP 205 Rebuild and Info
 

Jim, from all the info I could find I used the original sized seal. for the 30 spline, I believe the seal is a different part number. I am currently building a 32 spline front output 205 and that one is different from the 10 spline. I will try to get all the info up for you. On an interesting note about the front output yokes, I am using a 1350 yoke that came off a NP208. On the silicone, you can put it on right away. The key is more in cleanliness. You don't want any oil residue or contaminates where you are applying silicone sealant. You will want a clean surface for the sealant to adhere to.

Re: NP 205 Rebuild and Info
 

Just finished my NP205 rebuild out of my 1993 Dodge W250 Cummins truck. This thread was an absolute necessity...and I appreciate the time that was taken to document everything.

Bar none one of the best rebuilds on the net!!!

Re: NP 205 Rebuild and Info
 

Hey thanks on the great rebuild visuals! I had one tore apart for months and reassembling a couple of parts was kicking my behind! Thanks again. :metal::metal:

Re: NP 205 Rebuild and Info
 

Has anyone torn into their NP205 and found that the idler gear shaft only had one shim in it instead of 4?

I pulled mine apart this weekend and it only had one shim.

Thoughts?

'72 K20

Re: NP 205 Rebuild and Info
 

Mine only had 2, some i have done had 3 or 4 and different thicknesses.