77 F150 NP 205 transfer case leaks
 

So my transfer case has some leaks, looks like the front nut/washer for the idler gear and the rear access plate for such, Also it appears the rear output seal and housing gasket are leaking. My question is: For the front nut/idler gear, can I just remove the nut and put sealer under the washer and on the threads and retorque to 150 ft lbs and be fine? or is there a special procedure? also on the rear output shaft flange can I just remove the nut then slide pinion flange off and replace seal and retorque? or is it like the diffirential where a crush sleeve and rotational torque have to be set? I'm trying to reseal this thing without having to remove it from the truck.......any answers to these questions is appreciated.

Info on it. NP205 Rebuild Guide Step 7,8 ,13, 63, 74 ,77 ect...

Parts New Process NP205 Transfer Case Parts

so after reading that write up, it would appear I can just loosen the nut on the front idler bearing remove nut and washer and reseal? what seals fluid from coming out at the washer and threads? Can I just use a silicon sealer? Also can I just remove the rear output shaft as an assembly and reseal on a bench as they do and pop back in place? I'm trying not to remove the transfer case from the vehicle.

I have not dug into the rebuild thread, I am sure is can be done with the xfer case still installed, just not as comfortable. lol

I believe when there is not a call for a gasket or seal then YES you seal the threads of the bolts. I like Permetex red.

okay, cool,I guess I'll find out.......worst case, I'll end up pulling t-case, don't want to but to get to the top bolts I'll have to pull up the carpet.

so where do I get a seal/gasket kit? they list for direct mount and divorced???

I have two NP-205's, apart from my 76, that I am want to rebuild. One I want to double stick and the other I am putting in a 77 F150 resto project. Rich, are you recommending Torque King for the rebuild kits? I have never done this but it looks like a fun challenge.

I have heard good thing about TQ king and these folks. Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases

Pull the carpet, to get to the hump cover off, to get to the xfer case? You better double ck that you can get to it from up top, it might tbe further back?

I don't want to pull the carpet, I got the two tough bolts tonight .......I'm pulling the transfer case with the adapter still attached, I believe this can be done??

Yes very heavy, PITA, cross member might have to be slid fwd, or try to rotate/spin it out of the way. You can drill the bottom frame hole out a bit to get an extension to the upper bolts.

before I had read this post I had pulled it this morning with adapter still on and I was going to say that thing is one heavy mo-fo............but you beat me to the punch...lol.....so now begins the reseal, wouldn't mind using"torque king" but Montana is to far for quick standard shipping......gotta be a place closer to MD where I'm at. oh and I didn't have to slide /move the crossmember at all.

Here is a way to make it easier to get that thing out. lol

^^^no way on earth I'm doing that and risking a dent or scratch.....lol

If it easy if you use a cable come-along from the xfer case to the eng hoist hook and just leave the eng hoist in the same position. lol

Ah come on, be a little braver!