1st Gen transfer case

[edgeman]

Has any of you rebuilt a transfer case? I have a 1990 1st gen with a Getrag. The output flange for the front driveshaft is kinda flopping arround too much. I am useing this truck for snowplowing, so not driveing at highway speeds. It should be ok for a while, but starting to look at my options. Have never been inside a transfer case. Any ideas? Thanks, Larry

 

[HHhuntitall]

There are a few threads here and there. I'd suggest the Ultimate Crew Cab thread. BSchwarzli is doing a great job on his truck. Rebuilding from front to back. https://www.turbodieselregister.com...w-cab-ultimate-first-gen-pics-history-16.html

OK. The pics I have been promissing for a long time!



NP 205 starting from being pulled apart.



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Empty case:



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Clean off the magnet! You will be surprised what you find on it!!



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Watch the little needles... they will all fall apart when you pull it apart so this is what is should look like... .



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NOT like this:





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Install the gears. The fun part is getting the gears and shift forks all liked up to be able to put the lock rails in. Will make you develop a few new 4 letter words.



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[edgeman]

HHhuntitall, thanks for the reply. Wow, what a nice job BSchwarzli is doing! The rebuild on the T-case dosnt look too bad. Not sure if ill rebuild or try to locate a used one. Again, looking at my options. Thanks, Larry

 

[Simplysmn]

a complete rebuild kit is around 180. 00 has everything you would need to rebuild it I am getting ready to order a kit for mine foundout mine that I had sitting had Water in it be it a very small amount I think I am going to rebuild it and not have to worry about dropping it Twice .

 

[SAndreasen]

are you sure the nut that holds the flange didn't just come loose

 

[RSchwarzli]

Wow! You beat me to it! Was going to pull up those pics! Guess I wont! :-laf



I am a big fan of if it is out, just rebuild it as you never know where a used one might hav been. Did dirt get in the bearings? You dont know. You then install it and guess what? Its fails and you start all over again.



Took me a few hours and it was done. Only thing I will say, get a GIANT pair of snap ring pliers. Those things are brutal.

 

[HHhuntitall]

Oops, sorry BSchwarzli!! You've been so busy, I figured you wouldn't be around for a few days, so to help him, I gave him your info..... You do such a good job documenting your builds. I don't ever think about it until I'm almost done... .

 

[RSchwarzli]

No need to be sorry! I am thanking you! You go right ahead and help people where you can! In the last few weeks my actually getting on here is slim so good thinking with the post!

 

[edgeman]

SAndreasen, i checked the nut on the flange, it was tight. I actually took the nut off and tried to take flange off splined shaft, it pulled about 1/2" or so, but it wouldnt come off real easy, so i put it back on. Didnt want to go past the point of no return. I need this truck to plow the snow this winter.

BSchwarzli, did you have a print or assembly instructions to do the rebuild?

Simplysmn, $180 dosnt sound bad at all. Did you get the parts from the dealer, or NAPA?

Thanks for the help, Larry

 

[Simplysmn]

I haven't bought the kit yet but they are on Ebay all over the place just type NP 205 they will pop up

 

[edgeman]

Ok, Ill start looking. Thank you

 

[SAndreasen]

maybe your flange is just wore out on the splines but then your shaft splines are probably bad to. if you could get that flange off you would be able to check the bearings behind that flange

 

[RSchwarzli]

It is pretty strait forward but I have a factory service manul that kept me on the right track.

 

[edgeman]

SAndreasen, i was thinking the same thing when i tryed to take the flange off, but when it didnt pull right off, well, i started thinking about all the snow this winter. I sure dont want to shovel it! So i put the nut back on and figured i would ask you other TDR members b-4 going any further. Thank to all, Larry

 

[RSchwarzli]

The way that nut works it does hold in that flange. If you pull the nut the flange will slide off. That will tell you what you are dealing with. Do be mindful of the spider o ring inside the flange. It does into each spline to prevent leaks. If you are not careful you can rip it and then need a new one. So pull the flange off gently.

This rubber seal is normally that black thing you see when you pull the nut off and seal the end of the output shaft.

 

[edgeman]

Well, im glad its not too difficult. So far, this flange is the only problem that has showed up with the t-case. Mabe i can fix the flange & seal, and call it good? But will surely have to take flange off to see what im up against. My son plowed the snow with it last year, the only problem he noted, besides the flange, was that some times it wouldnt lock into four wheel drive, other times it would. Im not sure what to think about that yet. Looks like I will be plowing this year, so I can check it out. Still thinking about a complete rebuild next summer.

 

[SAndreasen]

see if you. can get that flange off then let us know mine had the same problem and luckily I just got the new flange and nut and seals and it fixed it

 

[edgeman]

SAndreasen, did you get the new flange at the dodge dealer or did you find one somewhere else?

 

[SAndreasen]

I got my flange from quad 4x4.com he had the flange and spline seals you might as well replace the seal on transefer case to . Also a good idea to get a new nut to

 

[edgeman]

Ok, thanks, I will look into that. I dont think i will tear it apart till spring tho.