Np205 question
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Tuned
Joined: Oct 2012
Posts: 251
Likes: 9
Np205 question
So my transfer case on my 77 f150 is leaking pretty bad. How difficult is it to replace the seals. Or should I have it rebuilt or replace? What's the cost on a rebuild vs replacement? Thanks in advance!
Cargo Master
Joined: Oct 2010
Posts: 2,674
Likes: 16
From: Ideeho
Seals aren't bad to do and wont cost much, whether you need a rebuild will depend on if the bearings are bad, causing it to leak. If its not making weird noises its doubtful that you need a rebuild. 205's are as tough as an anvil. Grab ahold of the yokes on the transfer case and give them a shake. There should be very little up and down/ side to side movement. I found a link to a post I did a while back on transfer case seal replacement:
https://www.ford-trucks.com/forums/1...placement.html
https://www.ford-trucks.com/forums/1...placement.html
Tuned
Joined: Mar 2015
Posts: 293
Likes: 45
From: In the 860
I did a full rebuild on the divorced 205 in my '75 earlier this year. I had a little bit of end play in the rear output, which wiped the seal out and was causing the leak. If you have end play, changing the seals is just a band aid.
That being said, they are very simple units, and you can rebuild one in an afternoon. I took the time to clean and paint everything, but for a simple R&R it could be done in an afternoon. There are a couple good pictorial how to's out there; google will help.
If you are reasonably mechanically inclined, its not a big deal at all. They fall apart. You do need a big socket (most how to's will mention this), a good set of drift pins, and possibly snap ring pliers. I say possibly because mine had some snap rings that required pliers, but some that did not.
For reference, the failure that caused endplay in mine were the needle bearings in the rear output cluster. They are loose in there, and changing them is tedious, but with a little grease there is nothing to it.
That being said, they are very simple units, and you can rebuild one in an afternoon. I took the time to clean and paint everything, but for a simple R&R it could be done in an afternoon. There are a couple good pictorial how to's out there; google will help.
If you are reasonably mechanically inclined, its not a big deal at all. They fall apart. You do need a big socket (most how to's will mention this), a good set of drift pins, and possibly snap ring pliers. I say possibly because mine had some snap rings that required pliers, but some that did not.
For reference, the failure that caused endplay in mine were the needle bearings in the rear output cluster. They are loose in there, and changing them is tedious, but with a little grease there is nothing to it.
Fleet Owner
Joined: Dec 2009
Posts: 20,678
Likes: 83
From: NorCal
I picked up a married 205 (and its mate a NP435) last year. Have yet to rebuild it but my research indicates a rebuild kit is about $250... a rebuilt unit is about $900.
I'm gonna twin-stick it for the helluvit.
I'm gonna twin-stick it for the helluvit.
Thread Starter
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Tuned
Joined: Oct 2012
Posts: 251
Likes: 9
ok my next question is how much do you think a shop would charge to rebuild it. cause I really don't have the time or the space to do it in. I have a place I can take it out and then take it into the shop but that's it. and how do you tell the diffence between a married and divorced? my truck is a 1977 150 4x4 with a 400m and 4 speed with granny gear.
Elder User
Joined: Jan 2003
Posts: 822
Likes: 0
From: Ilion Herkimer
ok my next question is how much do you think a shop would charge to rebuild it. cause I really don't have the time or the space to do it in. I have a place I can take it out and then take it into the shop but that's it. and how do you tell the diffence between a married and divorced? my truck is a 1977 150 4x4 with a 400m and 4 speed with granny gear.
Moderator & parts slinger
Joined: Feb 2007
Posts: 50,247
Likes: 5,815
From: S/W Missouri, Polk county
77F150 I bet it is "married"/connected to the transmission. If it is just a seal, (like the output flange) it is way easier to replace them without dropping it and doing a complete rebuild. Identify the leaking seal before you remove it, because it is HEAVY and a PITA.
NP205 New Process Transfer Case Diagrams and Information
Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases
NP205 Full Rebuild Kit
New Process NP205 Transfer Case Parts
http://www.midwesttrans.com/NP205_Transfer_%20Case.html
NP205 New Process Transfer Case Diagrams and Information
Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases
NP205 Full Rebuild Kit
New Process NP205 Transfer Case Parts
http://www.midwesttrans.com/NP205_Transfer_%20Case.html
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Fleet Owner
Joined: Dec 2009
Posts: 20,678
Likes: 83
From: NorCal
77F150 I bet it is "married"/connected to the transmission. If it is just a seal, (like the output flange) it is way easier to replace them without dropping it and doing a complete rebuild. Identify the leaking seal before you remove it, because it is HEAVY and a PITA.
NP205 New Process Transfer Case Diagrams and Information
Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases
NP205 Full Rebuild Kit
New Process NP205 Transfer Case Parts
NP205 New Process Transfer Case Diagrams and Information
Offroad Design - Complete Rebuilt NP205, NP203 transfer Cases
NP205 Full Rebuild Kit
New Process NP205 Transfer Case Parts
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Cargo Master
Joined: Oct 2010
Posts: 2,674
Likes: 16
From: Ideeho
LOL HIO.......I have redneck engineered some contraptions over the years as well! I think one of the most insane jobs I ever did was put a transmission in a grain combine on the side of a hill. Had to drag my service truck into it with a big 4x4 tractor. It was so steep that when I parked my service truck crossways on the hill and opened the doors on the service bed, my tools were falling out on the ground. Lots of come-a-longs, blocks, sheets of plywood and jacks of all sorts to get that job done. Back in the day, I could just pick a NP 205 up with no jack and stab it. Not anymore.......getting too old for that ****!
Hotshot
Joined: Feb 2004
Posts: 10,839
Likes: 2,612
From: The Shenandoah Valley
Right????
My '77's NP205 has always been wet on the outside since I can recall, I've only had it since 1986. I check it and rear end when greasing all them zerks on the driveshafts, frt axle, and steering and look it over.
Thread Starter
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Tuned
Joined: Oct 2012
Posts: 251
Likes: 9
thanks for all the input guys. ive got a pretty good idea which way im gonna go. if its more than the real seal then ill probably look it over and price a shop to do a rebuild. if its going to be more than a rebuilt case ill just buy a rebuilt case and sell this one. thanks again.