np205 help
 

Cant win for trying. Every time I fix one thing, there is something else that pops up. Received this truck from my uncle a while back and have been slowly working through things. Went to change fluids today for the first time since I received it and noticed the transfer case only had 1/4 quart gear oil. Thought, that's weird and topped it up. Took it for a long drive and noticed a good size puddle of gear oil on the pavement under the transfer case. It looks like it is leaking from the idle shaft nut on the front of the case. When I grab the nut on the idle shaft I can move the whole assembly up and down more than 1/4", and there is oil all around and under the washer! Whats going on in there? Any advice? I have a video but cant get it to marry up with my computer...

Re: np205 help
 

You might better luck in the 4x4 part of then forum,I'm sure the leak can be fixed but not sure if its a easy job or major rebuild.

Re: np205 help
 

First order would be to take off the idler shaft nut. Check out the case without removing the shaft. Look at the hole and see if it's worn or hogged out. If it is, looks like it is time to start looking for a case. If it is fine, clean up the area, put some silicone on it, and tighten to spec with some loctite.

Re: np205 help
 

Ill try that tonight, but currently the nut and shaft just spin. I can with 2 fingers spin it freely with no effort (shaft and nut together. Currently the transfer case is in nuetral, but I assume this does not matter. Seems that idle shaft is a press fit and should be stationary, but like I said it just spins.

Re: np205 help
 

Dont have an impact wrench, any other tricks to remove this nut? Is the spinning normal? All the videos ive watched it doesn't spin? Admin please feel free to move this to 4X4 if needed....

Re: np205 help
 

The idler shaft shouldn't move, the tapered bearings for the idler gears need to be loaded, like tapered wheel bearings. They use shims and a spacer between the bearings, and the lock nut sets the load tight. Maybe the nut came loose and the shaft hogged out the case. Lots of stress there.

Pretty much realized I have to drop my transfer case now. Took the 4 bolts out of the flange on the output shaft. Also took off the for nuts for the U bolts holding the rear drive line. Neither wants to break free though, do I have to undo the carrier bearing bracket and drop the whole back end to get it to pull away from the transfer case yolk?
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