NP205 problems

[nooblet]

I'm not sure where to put transfer case issues, so I put it here. Please let me know if this is not the correct place and I'll delete this and move it, or if a Mod could move it that would be great.

My transfer case crapped out on me the other day...I heard very loud rattling and snapping. I took it down and tore it apart and this is what I found. This is the np205 off my CTD.

Rear output - Is there supposed to be something where I've circled? It seems like there should be...





Rear of front output. That dowel pin looking piece is the shifter pin I believe.





So...do I need a new housing? I don't see how that broke, but there were small pieces of cast iron in the housing. No broken gears, no broken bearings. I guess the sound I heard was that piece of metal riding and binding in the gears? I'm not sure what I should do, what do you guys think?

Chris

[KTA]

Looks like the shift rail got bottomed out hard and broke the housing? I dont see any problems with running it like that though.

[nooblet]

Come to find out that little chip below the shift rail is supposed to be like that so oil can get slung up into that shaft. I found some metal on the magnet in the t-case, so my plan is to clean everything out real good, rebuild it, and see if that fixes it.

After cleaning some of the bearings real good and spinning them I think I found a couple bad ones. And I found a spring off a double lip seal on the magnet among the other shards of metal, so at some point a seal got blown. This explains the lack of gear oil in the t-case

There is already a really good write up on rebuilding a np205, and they are pretty simple anyway...so I'll prolly just post a couple pictures of it here and there.

Here is the write up on the np205 rebuild

rebuild

I got my rebuild kit here

rebuild kit

Chris

[nooblet]

Wow, I can't believe it took this long. I just put my NP205 back in my truck after spending the last two days installing the rebuild kit. The kit took 3 weeks to get here!

I'm gonna take some pictures of it and post them up tomorrow. I painted it blue, as close to color of the blue cummins emblems as I could find.

Drove it today, shifts through all the gears, no oil leaks, no bad sounds, I don't want to speak too early, but it looks like I successfully completed my first np205 rebuild

Chris

PS: if you have to rebuild your np205 DO NOT order a kit from Canada

[nooblet]

Pictures of my pretty BLUE np205 after the rebuild!





My rear output seal is leaking, other than that the rebuild went well.

Chris