NP 205 shift rail installation problem.

[70jimmy]

Ok so I followed all the instructions on how to remove and re-install the shift rails, and I learned how to get the shift forks back in position after the allen wrenches fall out of place.

So I install the front shift rail per instructions, then move to the rear. When re-installing the rear shift rail the detent ball on the side will spin but not move inward so the rail will only go as far as the end of ground part of the rail and then the detent ball on the side wont let the rail go in any further.

I have lubricated the ball and it spins but doesn't push in at all. Is there a way to get it to loosen up or do I just need to apply some pressure to get it past?

I noticed the old rail had a pretty good mark from the ball.

Thanks

 

[sweetk30]

its not a ball its a pair of rods .

and if front range rail is in wrong position you cant install rear range rail.

check in here for full blowup and reman of a 205 to understand the workings. http://coloradok5.com/forums/showthread.php?t=253000

 

[70jimmy]

Wow!!! Great write up!!!

Thanks to you and ORD I got them in. Yep Rear rail was in wrong position, I couldn't get the front rail in until I put in the roll pin for the rear rail, then the rod moved allowing the front rail to go in (almost). At the back of the case there is another rod that was blocking the way fro the front pin to go all the way into the case. Just had to rock the case back then that got out of the way.

Now to run to the parts store and on to the next challenge. Mounting the 205 to the 203 and getting the triple stick shifters all test fitted and working,

I may have to disguise my voice next time I call ORD otherwise they may start hanging up on me or say you have reached your daily limit of stupid questions, try again tomorrow!!!

 

[sweetk30]

best thing i can say from doing a few ord twin and tripple shifters .

mockup out of the vehicle if at all possible if tcase setup is NOT installed yet. so much nicer to get all perfect before you get it up in there with no room .

 

[70jimmy]

Yep gonna get it all fitted on the bench, then un-assemble what I have to so I can mount the units separately then re-assemble.

I figure it will also give me a chance to make sure everything shifts fine.

Had to order some gaskets anyway since nobody carries NP205 gasket sets in stock around here. I was also told at one of the parts stores that Chevrolet or GMC never put NP205 in their trucks only Ford did and Chevy and GM used Chrysler transfer cases.

 

[sweetk30]

does he also sell muffler bearings and headlight fluid ?

also ord has about the best deal on master gasket/seal kit for 205 i have found.

and if you havent do the 203 shifter detent mod i wrote up in that build thread.

 

[70jimmy]

That detent mod looks easy enough! Might have to do that.

Another questions what does the triangular bracket bolted to the outside of the 203 do? Its holding a pin with an edge in line for some reason???

 

[70jimmy]

Ok looked at it again.

but leave 1 lower hole open to have a place to bolt on the custom lock plate for the lower gear set main pin.

next take the lower gear set main pin and set it in the case and clock the flat side to the 1 bolt hole. then take a small piece of flat stock and make a simple tab to lock the pin from possible ever coming out and or spinning in the case. (pic#4-5)

is this something I can do without tearing into the range box???

 

[sweetk30]

if using stock tranny to 203 adaptor its not needed.

i did this as i redrilled the face for a later 241 adaptor.

 

[70jimmy]

Thanks. I will have to look and see if I need to block the bolt holes if they go all the way through. It would be bad to discover a huge gear oil leak could have been prevented.