How to rebuild a Chevy NP 205 Transfer Case “Assembly”

[@1976chevyboy]

This was great, absolutely loved the instructions without a bunch of rambling and just showing what takes place instead. 10/10

[@72cool]

Thanks for posting this....The PVC pipe idea was a game changer....Helped me rebuild my NP205 for my 72 Chev.....thanks again..Great Video!!!

[@MrGregault]

Great job showing the important stuff and not even lacking on a few great tips along the way! Thanks!!

[@cs2-llc]

I'm a little late to the party, but I have that manual, and I love the format you did this video in. Just straight up assembly. This will help me tremendously. I have my Ford NP205 apart as we speak. Pretty much exactly the same. Thanks for taking the time to do this.

[@KeepItSimpleOffroad]

Better late than never 👍🏻

[@panamaonthecheap]

Thanks for the video, this will help immensely!!!! I don’t usually watch tube videos because I can’t stand the guys doing the videos stammering and trying to fill the video with useless banter. This video is perfect! No BS just build

[@KeepItSimpleOffroad]

Scott Schartz man I feel the same. Just get to it already. Even this video now when I watch it I could have cut half the beginning intro out.

[@rheaghen]

I couldn't agree more! And he covers the tedious roller bearing assembly! Thank you sir!

[@KeepItSimpleOffroad]

Ryan Mack thanks

[@RickDominick69]

I ran 2 times to my garage and fixed two things that another build vid left out. Very good video. The lighting was spot on.

[@KeepItSimpleOffroad]

Rattlecan Restorations awesome glad it helped

[@sonnywillier9419]

Great video! I like the format that I can pause when needed, and follow along while working. I used it while I was rebuilding my case. Only problem is greasy fingers on my screen to pause it! Thanks.

[@KeepItSimpleOffroad]

Sonny Willier glad it helped. Ya the ole greasy finger bs. Thanks!

[@ebluvr72]

Great video. Right in the middle of a Ford NP205 Rebuild and already had the manual you showed on the way, but I'm not sure I need it after watching your video. Other videos I watched left out the checking of the endplay. I'm sure the manual will explain that in detail. Liked/Subscribed! Thank you!

[@KeepItSimpleOffroad]

The manual helps a bunch and has other versions in there. It’s worth it all the way. Thanks for watching

[@matthewszady7727]

Man thank you so much for the video! This helped me SO much! I even played it just to listen to the music while doing my 205. I really appreciate the time, detail, and effort. I had never done this before and it seemed very complicated to me. But this helped make this something that I could do on my own. Thanks again!!

[@KeepItSimpleOffroad]

That’s fantastic!! Great job!

[@EKonMaster]

The way you do it is the best! great video quality and good music, make more videos like this.

[@KeepItSimpleOffroad]

EkonMaster Bud thanks. Will do.

[@SubePelayo928]

Awesome! I’m swapping a 355th400 Ana np205 into my 4runner! About to go through a rebuild and twin stick it

[@andrevaldez114]

Bro I like how you do your work you shoe everything you do step by step your the best one I've seen yet your a good teacher all the other guys suck they don't show any work being dun to it keep up the good work

[@KeepItSimpleOffroad]

Thanks

[@mikeinnes9998]

Good video I just took my 205 apart last nite cleaning things up to day working up a parts list. Good music and format ! paused and checked things I need to ck. Further into. I wish I would have caked idler endplay before I took it apart I only found one shim. thanks again

[@KeepItSimpleOffroad]

Mike Innes thw is for the comment. That’s a good point to check end play before year down just to see where you are at

[@unprofessionalsllc6273]

Nicely done. I will be using this video in the future for rebuild I got to do.

[@KeepItSimpleOffroad]

UnProfessionals LLC great. If you have questions feel free to get in touch thanks

[@lokihallow]

I'm currently putting my np203 back together and trying to figure out my needle bearings or rather he long skinny ones but seeing how you used the assembly lube is gonna help alot

[@KeepItSimpleOffroad]

lokihallow right on!!

[@jamesford2942]

There is a guy who does a rebuild on a 203 that is like this video. It's titled "NP203 reassembly" watched it a couple times today.

[@phoenixdynamometer1]

What an amazing video, thank you very much! Probably saved me $400 so I can do it myself. I'd like to see a video for the TH400 (4WD) if you ever have the time.

[@KeepItSimpleOffroad]

tobedetermined thanks. If I get the opportunity to do a th400 I’ll be sure to film it. Thanks for watching!!

[@phoenixdynamometer1]

@@KeepItSimpleOffroad This is exactly the way "how-to" videos should be done. Great camera angles, clear instruction, clean workbench, etc. Well done sir!

[@cougsix]

Awesome - thanks for posting this.

[@ob0ne11111]

Nice, vid. I’m rebuilding mine and had few questions answered by your video. Bought my 205 for 300$ but find it had twisted splines on the input shaft (27 splines to th350). I just received the new shaft and will finish it today.

[@KeepItSimpleOffroad]

ob0ne11111 that’s awesome. See someone else might have just put it back together! I just added the magnum box to mine. So I went through it again and used the video instead of the book lol. I prefer seeing it. Thanks for the comment and glad it was able to help you.

[@jamesford2942]

Nice how to on the 205. Doing one right now except that it is the synchro style K30

[@KeepItSimpleOffroad]

Thanks

[@kylestalter3489]

Just came across this video. Hope you are well. Appreciate the content!! You asked for feedback: I’d encourage you to do this style visual edit but with voice over instructions / narration. 👍👍 love the quality of work, the case looked really professional after you were done. Great prep and execution! Wondering why not set it up for twin sticks??

[@russellapplegate5661]

Great video. Helped me out a lot!

[@KeepItSimpleOffroad]

Right on thanks

[@travistorres1388]

Legit video. Thanks!

[@ryany4941]

Does it matter which way the front out of her collar goes? Also does the thrush the washer orientation matter?

[@15Muleskinner]

Awesome video

[@KeepItSimpleOffroad]

Brock Last thanks

[@johnnydoe4677]

Man...i really wish you would repost this without the music and explain what you are doing as you do it...and give us helpful tips and tricks....cool video....

[@KeepItSimpleOffroad]

Thanks. I wanna say you’re the 1st person to ask for that. Most prefer no talking. Lots of people have asked questions in the comments which all have been answered. The only real tricks are the light in the roll pins and the plastic pipe that gets pushed out. Both are in the video. Anything I can help with specifically ask away or send a dm. Thanks for watching!

[@WakeMarine]

Howdy. At 11:33, how did you toque that nut without the gears moving on you? Thanks.

[@KeepItSimpleOffroad]

WakeMarine the idler shaft should not spin. The gears will spin.

[@WakeMarine]

@@KeepItSimpleOffroad Thanks. Your thoughts on Timken vs Japan bearings? At the time I couldn't get a hold of Timken back in 2005.

[@KeepItSimpleOffroad]

WakeMarine I do prefer Timken. I look at it like this. If it’s easy to get to replace and I can’t get a timken quickly I’ll use whatever. But if it’s a PIA to get to I’ll wait for them. Amazon pretty quick.

[@jamesnorth1063]

I'm afraid my NP205 has excessive gear lash - I get a clattering noise when freewheeling (not under load). Is there a way I can test for this such as excess movement of the input shaft relative to no movement in the output shaft? I couldn't see anywhere in the video that this could be adjusted, so is the only recourse to buy a new gear set or are there shims and measurements somewhere that I didn't see in the video?

[@KeepItSimpleOffroad]

It’s not in the book. But somewhere in the comments someone with a fire had the same issue. He found a small Flat bearing that solved his problem. It sounds like the same for you. I’m guessing though. Dig through the comments. I’ll dig through the DM’s and see if o can find it. It was a flat washer with roller bearings.

[@buckybell8363]

Looks good. Thinking about rebuilding mine myself. It's for a 80 GMC What kind of cost I'm I looking at? I have the gasket set already. It's made a chunk since the early 90s.

[@KeepItSimpleOffroad]

No way to tell until you open it up and look for damage.

[@buckybell8363]

D'oh

[@SSTools1]

Is there a snap ring installed at 18:10 - 18:18 or does the 4 bolt cover hold the bearing and the rear cover hold the shaft?

[@KeepItSimpleOffroad]

No snap ring yes the cover holds it into the case.

[@phoenixdynamometer1]

Would you be able to post a list of the part numbers you used for the rebuild? Did you have to purchase individually or do they make a rebuild kit? Thank you.

[@KeepItSimpleOffroad]

tobedetermined it was a gasket kit I got on eBay I don’t recall the number but I bought an expensive one from a Offroad shop and the eBay one and both were identical right down to the numbers on the seals. Ebay was cheaper. The part can be found at torqueking.com/category/chevy/ as well as the book.

[@dieselguy9950]

Is there a max number of shims for each side on the idler gear? With no shims I have 0.150 play

[@KeepItSimpleOffroad]

Diesel Guy not that I am aware of. Get it within spec and roll with it. Make sure you are torqued to spec each test

[@joshh6470]

Nicely done

[@KeepItSimpleOffroad]

joe endo thank you

[@billchaff333]

the thrust washer pins come in a package of two. are they both used in the chevy np205. thank's for the video. or do they sell them this way because the nv4500 has two?

[@KeepItSimpleOffroad]

bill chaff Hi Bill. It does use both pins. One at 4:05 and the other at 6:30. It’s not real clear on the second one. Thanks for asking. Hope it helps someone else.

[@billchaff333]

@@KeepItSimpleOffroad thank's i watched it again went and took it back apart. it was missing. that snap ring is a beast.

[@KeepItSimpleOffroad]

bill chaff right. A good set of snap ring pliers helps.

[@daved3549]

Good video. Question at 10:54 when checking end play with dial gauge how do you make adjustments to this play? Do you use shim's?

[@KeepItSimpleOffroad]

Dave D yes correct. I used this kit torqueking.com/product/2053/tka2053-9-piece-idler-gear-and-output-shaft-shim-kit/.

[@daved3549]

Thanks for reply kind Sir 👍

[@duramax78]

Hi from Alberta, Can someone please helpppppp, I have a 2009 Escalade ext awd, I have to sun gears seems like only 1 will fit at a time is there a trick to get the suns on.?

[@KeepItSimpleOffroad]

Ranjit is like to help but don’t understand your question what are the sun gears.

[@KeepItSimpleOffroad]

Ranjit also you will have a different tcase than this one so I won’t be of help anyway. Sorry

[@jcperea69]

Following this video as I rebuild. Great stuff. Installing my idler shaft and torque and torqued to 150lbs. Zero end play and the idler spins with some resistance. The bearings are brand new. Is this common?

[@KeepItSimpleOffroad]

So if I remember correctly the shins are to get you into the correct pressure. If you have no shims it squeezes the case to tight. You’d end up with no end play and the bearing would be too tight and end in failure. I’ll have to refer back to the book tonight and get back to you. If someone else can chime in that knows for sure feel free.

[@jcperea69]

@@KeepItSimpleOffroad Thanks for the response. I currently have all 4 shims in as there were 4 in there when I disassembled. Each shim is 1/64.

[@jcperea69]

@@KeepItSimpleOffroad With all 4 shims and 150lbs there is no end play. the gear spins but freely. Not sure if this is because the bearings are new? Should I remove shims?

[@affordabledcgenerators1607]

I'm putting my 205 back together, its a figure 8 with a TH400 adapter. The adapter doesnt sit flush on the front of the tcase. There is a small gap. I'm guessing the adapter is supposed to be tight against the bearing snap ring and the paper gasket will fill in the gap. Does that sound right?

[@KeepItSimpleOffroad]

Yes there are places that the gasket must be in to torque. I’m not positive on that exact spot though but if it looks like it the same gap I’d be ok to do it. If you ever have questions you can also check out the NP205CASES on IG. Dudes name is Todd and very very knowledgeable!

[@affordabledcgenerators1607]

@@KeepItSimpleOffroad Thanks for the feedback!

[@jason86768]

How far do you tap in the needle bearing cup on the front output rear aluminum plate?

[@KeepItSimpleOffroad]

I did it flush.

[@ebluvr72]

Quick question. When installing the yoke for the rear output, the splined rubber seal won’t slide down along the splines of the shaft more than 1/8”. Did you experience this?

[@KeepItSimpleOffroad]

I did. I found the one that fit the best and siliconed the splines as well

[@RickDominick69]

I put the sim pack on the little gear side will this cause any problems?

[@KeepItSimpleOffroad]

That’s what I did too. I’m not sure. I’ll double check the book and reply today but it’s worked that way for 5 years no problem

[@RickDominick69]

Question the shim do the four go on one side or 2 on both sides?

[@KeepItSimpleOffroad]

I did mine on one side

[@juanfo7307]

What if the front output has some residual drag in neutral and rwd?

[@KeepItSimpleOffroad]

juan fo I would try to find out why. It will feel heavy because you’re turning gears even in neutral. Is that what your having?

[@juanfo7307]

Thank you for your help KISOR. The issue is if the input turns, the front output yoke also turns. I can turn the input and hold the front output to stop it from turning.

[@KeepItSimpleOffroad]

juan fo as long as you don’t feel teeth or anything binding you’re ok. Mine will do the same. The front out put will spin a little bit it stops usually after the oil has warmed up.

[@firechicken6667]

I disassembled my np205 and It doesn't have the rods between the shift rails. Is that normal on some years? The case is dated 79.

[@KeepItSimpleOffroad]

No. Those rails keep it from being able to put one axle in low and one in hi. That’s not good.

[@firechicken6667]

@@KeepItSimpleOffroad ok so obviously it's been torn into before... I'm also doing a twin stick conversion, would I still need them? If so I have to figure out where to find some. Thanks for your reply!

[@KeepItSimpleOffroad]

@@firechicken6667 yes even twin sticked it needs them. Call Tod at Np205cases.com 562-972-1570 if he don’t have them he’ll know who does.

[@vikinghauler3244]

Is it necessary for full torque to check idler clearance?

[@KeepItSimpleOffroad]

VikingHauler yes it’s compressing the case