Thought I would post this for other users who have to handle a NP205 transfer case for installation or rebuild. I made the jig out of Unistrut, which you can find at the big box stores. I secure the case to the jig with 2 of the factory side mounting holes. I have it mounted to my engine stand for a rebuild, the jig was stout enough that I could lift it and the transfer case with my engine crane to mount it to the engine stand. It also allows access to all sides except the PTO cover, but during the rebuild I don't need that. When the rebuild is done, I will then bolt the jig to my floor jack trans adaptor to slide the case onto the trans output. The jig keeps the case in the correct orientation for installation.

 

pretty good idea,looks good to.

 

Cool idea
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Thanks for sharing, good idea.

 

"Pretty Slick Deal" there!

 

Holy mother of unistrut goodness that's freakin' awesome.

 

Been wanting to make one of those for years....nice job!!!

 

Thanks for the feedback, hopefully it can help someone else handle one of these. The NP205 has to be the most awkward part I've had to handle on a vehicle, ever. And they're heavy as heck! I'll update this thread with pics when I go to install the unit in the vehicle.

Once I get the rebuild finished, I plan to post about the experience. This is my first NP205 rebuild, I have rebuilt other transmissions before and I learned some important things on this one.

 

Rep worthy post imo.

 

Absolutely! More pics of this awesome jig! Never heard of Unistrut before.

David

 

X2 on awesome looking jig, maybe this will help with the rebuild?

New Process NP205 Transfer Case Parts

Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases

BillaVista.com - Offroad & 4X4 Tech Articles by BillaVista

AWESOME NP205 Rebuild Guide

NP205 New Process Transfer Case Diagrams and Information

 

Hi David,
Unistrut is used extensively in the Electrical industry to mount conduit and boxes to the building structure. Unistrut is actually a name of one company that makes the "building channel", its like the name Kleenex. Its relatively cheap for its durability, its around $15 for a 10 foot section of perforated shallow channel. It also has a channel in it that holds a threaded nut, and this nut is captured in the channel so that it doesn't spin when you tighten the bolts. Its like an erector set for us bigger kids.
77&79F250, thanks for the links. Just finishing up the rebuild, had problems with a kit that I bought off epay. I'll post about the issues on another thread.