Hi , I am pulling out my NP205 for the first time and I was wondering what the best way to do it is?
DO I remove the shift linkage and unbolt the case from the trans adaptor and drop it out OR do I unbolt the trans adaptor from the trans and pull the adaptor out attached to the case?
I am just looking for pointers now so I don't have to learn the hard way while I am under my Bronco in the driveway this weekend!
Thanks

 

I would undo the linkage and take the six bolts off that hold it to the adapter. It is really heavy, though, so be careful.

 

I dropped mine with the shift linkage on there though I reinstalled it with no linkages. I agree with Ted, try to pull the bolts that hold the t-case to the adapter if you can. If you pull the adapter off the tranny there will be another seal in there you'll need to replace. Also, don't know how your clearance is but if the t-case sits very close or snug against the floor pan I would loosen all the bolts on the crossmember so that your t-case will hang down a couple inches. This will make it easier to remove and also much easier to reinstall as the input shaft can be hard to line up without enough clearance.

To save the chance of spilling stuff all over drain the fluid out of the case. If you have an auto tranny drain it as well or you'll leak AT fluid all over the place. As Ted said these cases are heavy, about 160 pounds so try and get a floor jack under there to support it with a friend to lower the jack while you balance the t-case on it. If you're a strong guy I find it's much easier to just set the t-case on your chest and "bench" it back into place when it comes time to install it. Otherwise you're going to have a major fight with balancing it on the jack and getting the shafts lined up.

IF you have a welder and some scrap iron check out this article: https://www.ford-trucks.com/articles/np205/index.html I was thinking of building one when I did my case but decided to go the strongman route.