Attention: TDR Forum Junkies 
Parts Needed to convert a Gas Engine/Automatic NP205 Transfer Case (mine was a 1985),
To a 1991 Cummins Diesel/Getrag 5 Speed NP205 Transfer Case. NOTE; This does NOT include changing the rear output shaft/case assy/drive shaft yoke. If you want to use the larger U-joints and yoke assy, you will also need to change the output shaft/bearing/snap rings/rear housing assy.
You will need to completely disassemble the transfer case and have the main case machined to accept the larger input bearing. The tear down of the NP205 is not very hard, but I do recommend that you have a OEM manual for your truck before you start. Also watch out for the two ball bearings from the shifter position assy.
This posting is for REFERENCE ONLY, please make sure to verify EVERYTHING before trying this. The prices I have listed are what I paid at a Dodge dealer and Napa.
By the way I did find a rebuilt NP205 for a Diesel $1100 exchange.
Kyle
Qty Dealer# Description Price
1 4505305 AdapterT 21085009 $364. 00
1 Dealer# Imput Shaft/Gear $203. 00
1 Dealer# Coupler $58. 00
1 4269183 Imput Bearing41005001 $52. 96
1 2124518 Snap Ring21009023 $1. 80
1 2960192 Ring Imput 21009023 $1. 48
1 4269183 Seal oil 21060012 $6. 36
1 4505307 Gasket AD 21004003 $3. 00
1 4340247 Gasket TR 21004003 $1. 53
1 517351 Gasket TR 21004003 $1. 89
1 4210975 Gasket OU 21004003 $1. 35
1 2225039 Gasket OU 21004003 $1. 35
1 4210976 Gasket GA 21004003 $1. 53
1(Napa)21213 Oil Seal $8. 99
1(Napa)17720 Oil Seal $9. 59
2 Lost Part# Shifter Fork Oil Seals
$4each $8. 00
1 Transfer Case Machine work and
cleaning $40. 00
Approx. Total $764. 83
------------------
1985 DODGE 1 ton Crew Cab(imported from California with no rust) W/8' box converted to 4X4 in 1999. Converted to a non-intercooled 1991 Cummins Turbo diesel & 5 speed Getrag in 2000(wife can't drive a stick
. Freshly rebuilt and balanced Cummins. Rebuilt Injector pump and tweaked. 4:10 gears, limited slip rear end, 205 transfer case, 16" Goodyear GSA Wranglers and LE Package and a Sony CD Stereo. Next add-on some “Banks” toys ! Wish Dodge would build a new Crew Cab in 1 ton. Last year for the Crew Cab was 1985. If you want to know why I did all of this, 2 kids, one on the way and I can't stand Ford and Chevy. Kyle Hoover ,Fruitport, MI.
To a 1991 Cummins Diesel/Getrag 5 Speed NP205 Transfer Case. NOTE; This does NOT include changing the rear output shaft/case assy/drive shaft yoke. If you want to use the larger U-joints and yoke assy, you will also need to change the output shaft/bearing/snap rings/rear housing assy.
You will need to completely disassemble the transfer case and have the main case machined to accept the larger input bearing. The tear down of the NP205 is not very hard, but I do recommend that you have a OEM manual for your truck before you start. Also watch out for the two ball bearings from the shifter position assy.
This posting is for REFERENCE ONLY, please make sure to verify EVERYTHING before trying this. The prices I have listed are what I paid at a Dodge dealer and Napa.
By the way I did find a rebuilt NP205 for a Diesel $1100 exchange.
Kyle
Qty Dealer# Description Price
1 4505305 AdapterT 21085009 $364. 00
1 Dealer# Imput Shaft/Gear $203. 00
1 Dealer# Coupler $58. 00
1 4269183 Imput Bearing41005001 $52. 96
1 2124518 Snap Ring21009023 $1. 80
1 2960192 Ring Imput 21009023 $1. 48
1 4269183 Seal oil 21060012 $6. 36
1 4505307 Gasket AD 21004003 $3. 00
1 4340247 Gasket TR 21004003 $1. 53
1 517351 Gasket TR 21004003 $1. 89
1 4210975 Gasket OU 21004003 $1. 35
1 2225039 Gasket OU 21004003 $1. 35
1 4210976 Gasket GA 21004003 $1. 53
1(Napa)21213 Oil Seal $8. 99
1(Napa)17720 Oil Seal $9. 59
2 Lost Part# Shifter Fork Oil Seals
$4each $8. 00
1 Transfer Case Machine work and
cleaning $40. 00
Approx. Total $764. 83
------------------
1985 DODGE 1 ton Crew Cab(imported from California with no rust) W/8' box converted to 4X4 in 1999. Converted to a non-intercooled 1991 Cummins Turbo diesel & 5 speed Getrag in 2000(wife can't drive a stick
. Freshly rebuilt and balanced Cummins. Rebuilt Injector pump and tweaked. 4:10 gears, limited slip rear end, 205 transfer case, 16" Goodyear GSA Wranglers and LE Package and a Sony CD Stereo. Next add-on some “Banks” toys ! Wish Dodge would build a new Crew Cab in 1 ton. Last year for the Crew Cab was 1985. If you want to know why I did all of this, 2 kids, one on the way and I can't stand Ford and Chevy. Kyle Hoover ,Fruitport, MI.
