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I have a 77F150 with the C6 and NP205. When coasting then going to accelerating, there is a clunk out of the transfer case, as well as when going from reverse to drive. Plus there is a high speed vibration that goes up and down directly with the speed of the truck.
I need to know if this sounds like bearings or gears going out.
Also, who sells a good rebuild kit for this unit if any, or do i have to go and strip a wrecking yard unit?
It could be berings but the clunk sounds like a problem i had with the same set up I found the nut holding the rear drive shaft yoke on to be loose. You might want to check that first. I retorqued mine and it took care of the problem.
Sounds like it is time to rebuild, I had a similar problem in a 208. The thrust washer wore out and eventually ate through the shift fork. That thrust washer prevents the horizontal component of the force being applied by the engine via the tranny (which may also have a thrust washer or bearing) from damaging components in the transfer case. If it wears out it will clunk and may lead to worse outcomes. Mine eventually caused the pinion bearing retainer in the rear to break and the aforementioned shift fork problem.
Keep in mind that my problem was with a 208 and not the 205, but if you are sure that this noise is coming from the xfer case, then you should drain and drop it, or take it in.
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