Killed my NP205

[MrWinkey]

Well hello agian I used to post on here some under the name ofitzgerald and I just re-uped agian because things get busy here in winter and I'm old.....



Anyways onto the good story... ... .



I was hearing a noise while in 4wd and it sounded like a bad U-joint. It wasent very loud so I was going to limp by for a bit as it has been very cold up here in the north west. Well turns out we got a bunch of snow and I needed the 4wd to make it up my driveway.



Well I had it on the floorboard going up the hill I live on and BANG! :--)







No more 4wd and it kicked the shift lever out into 2wd. Had the wife crawl in and put it in 4wd agian and nope no front drive shaft spin.



Tommrow I'm going to pickup a good used unit but has anybody put in a heavier duty T-case?



I'm a lil concerned about the 205 now after this as I sometimes need to go up my driveway that's on a pretty big hill and as this time there was about 2 feet of fresh snow. I had just unloaded 2k worth of pellets from the back of the truck and remberd I forgot to get the mail so went back down to get it when I lost the T-case 20 feet from the top.



Thanks in advance

 

[Flexiheep]

Sorry to hear about the 205 quiting, also sorry to say that your probably not going to find a stronger case either. The 205 is reguarded as the king of light duty cases, and ours is the best one they made I believe (larger input/outputs mainly). Take a look at it and let us know what you find broken.

 

[Fendley]

you might give advance adapters a call. I know their atlas line of transfer cases are strong, but i don't know if they will survive behind a cummins for long.

 

[Nate]

And they are around $2000 too

 

[MMiller]

Unless you are turning a bunch of power and truck pulling with big twins, and a big gear, the 205 will be more then enough for your truck. No need to go any heavier. I would suggest making sure the linkage is not so worn that it won't fully engage into 4X4. It popped out of 4x4, but then when put back in, did it make more noise? I've never been into a 205, but it sounds like the mechanism that locks the gearset for the front output to the rear output is not engaging. I would be suprised if you are really moving the shaft(linkage) into 4X4 and spinning the back tires, and not having any grinding, or banging of broken parts in the t-case.



Have you tired low 4X4?



Michael



Edit***Unless it has been driven with no oil in it, or completely overpowered and tied down, 205's are just darn near indistructable. They start breaking output shafts when put behind a 850+ hp big block, and tied down to a clay track, pulling a sled, with a tall gear in the transmission.



Michael

 

[glhs]

There was an article for a complete new heavy duty 205 case made with 3:1 low range in Jan 07 Diesel Power magazine for about $2000. Heavy duty lower range gear kit sells for $1100.

 

[DVolk]

Killed my NP 205

Im almost certain you didnt blow your t-case up ,



If you pull the drain plug do you get any peices ?????



On my 92 it wont go into 4 low im 95 % sure its the shifting rails are the problem , it works in 4 high , will yours work in 4 high , my guess it does



the problem is caused by the stupid gated shifter , im still trying to figure out how to scrap that set up , id like to install the shifting rails that offroad design sells and there cheap , the problem is how to fit a twin stick and mount it , any one done this or have ideas ?????



the other high possibility is that you blown a hub or poped a hub ,

or litterly snaped a axel , id check the front diff



Only one other t-case stronger than the 205 and thats the military ones or the full blown direct drive off road puller type

 

[MrWinkey]

Lets see if I can answer all the questions.



Yes I'm sure it was the T-case and not an axle. I also tried 4-low and the tires did not spin then either. The front output of the t-case did not spin at all in any setting.



Yes I might of bent/broke a shift fork.



I plan on pulling the case out tonight or tommrow. I found a good used case so I'm going to throw that in and run it.

 

[Jong]

You won't find a much tougher transfer case than an NP205 unless you go to a Rockwell or something similar. The NP205 is easy to rebuild, they are just like a manual transmission without synchros. They use a shift rail, and usually use a straight pattern shift. DVolk, the shifters mount to the transmission/transfer case adapter usually, and putting the twin sticks in is easy. If you want the option of front wheel drive or rear wheel drive ONLY, you need to grind down the shift rails and remove the interlock pills in the case. The best place I've seen for rebuild kits is www.quad4x4.com. Good luck!

 

[DValentine]

The Rockwell 221 was used in light truck applications. I have had two in 60's vintage chevys... . a divorced case. It too had weaknesses. It had an upper bearing that didn't get lubricated very well well. Good luck with your T case.



Dave

 

[DVolk]

Killed my NP 205

I know the tricks on the t-case to convert it to twin stick



by changeing out the rails , the problem is the mount for the sticks



know body has came up with a dodge setup , the only nv4500 one i seen is a ford setup and some of the jeeps all with the driverside diffs no body with the passenger side diffs , if any one has a trick and is makeing them ill take two if the price is reasonible .



Ive been in a couple ares were front wheel drive would have been nice , but the low range is nice backing trailers though

 

[MrWinkey]

Well... ...



Got it in the shop and started to disonnect everything to drop out the T-case and have a look. Got to the part where you disconnect the drivelines and what the !@#$



No bolts in the front drive shaft. One snaped part of the ear off the collar. The other snapped the bolt off.



So I guess the lesson is always use thread locker on most everything.



Yep it was a dumb mistake but I'm just pretty darn happy I didnt have to rebuild the T-case.

 

[GIT-R-DONE]

Sometimes things actually do work out for the best. More $$ in your pocket now that you didnt have to go through all that.

 

[bgilbert]

I use a longer bolt that threads through the yoke flange at the t-case front output. Then a lock washer and nut holding it.