205 Transfercase Speedo Gear R & R

[78blazaer]

My speedo stopped working, I pulled the speedo cable at the t-case side, found that the speedo plastic gears teeth are all gone inside the t-case. How do you replace the speedo gear inside a 205 transfer case? Do I need special tools? I know for sure I need to remove the nut that is holding the yoke, plus the little housing etc.. Do I need to a bearing puller?
Can someone please enlighten me on how to replace the plastic speedo gear inside a 205.

Thanks in advance!
Tom

 

[4X4HIGH]

Well are you sure it's the drive gear (the gear on the 205 output shaft) or the driven gear (the gear that messes with the drive gear)? There are two versions of the drive gear, one is steel and one is plastic. I think the plastic gears only came on the later 205's with the slip yoke and are splined onto the output shaft whereas the steel gear is a smooth ID and just slips onto the output shaft. At any rate, since you said you would need to pull the nut holding the yoke then you have the earlier version (1980-down) just remove the nut and yoke and then the seal retainer and then you'll see the output bearing and you can work it off usually with a screw driver and a slight tap of the output shaft and then you'll be able to remove the speedo drive gear. You might need to remove the 9 bolts holding the cast iron speedo housing if you can't retrieve all of the broken gear pieces. Beware that on some of the 205 cases if you have to remove the cast iron speedo housing there is a torrington needle bearing that has either caged needle bearings (no problems) or non caged needle bearings (going to fall all over the place). Don't forget that you will first need to remove the driven gear assembly from the outside of the speedo housing (1 1/8" socket).

 

[78blazaer]

I removed the driven gear assembly from the outside of the speedo housing and I can see that the drive gear on the output shaft is shreded. The driven gear is fine. It's made out of metal so that survived and the plastic didn't.
I will attempt to do this thing tomorrow and I'll to take some pictures. Thanks again, I appreciate all the info.