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NP205 rebuild

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pseudomike

1/2 ton status
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Dropped and started disassembling the old NP205 today. It has never skipped a beat and makes little or no noise but it leaks like hell and the front output shaft has forward-backwards play in it. It also was shifting hard out of 4wd, let me rephrase hard, I had to "feather" the pedal to get it out of 4wd just about every time. I think the case has a little over 260k miles.

I've never tackled one of these before though I'm told they aren't too difficult a case to rebuild. I have some good snap-ring pliers and a few exploded diagrams. Any advice? I haven't ordered any bearing kits yet because I have a hard time believing the bearings have any issues w/o being noisy. Definitely going to need a seal kit. How about hard parts I may want to inspect? What have others seen when rebuilding these (looking for the experience stuff not found in the manual). Not sure what is causing the front output play but I'm guessing a worn thrust busing or shim. Hard shifting? Instinct says fork but I see a bunch of detent pins and balls and my guess is they may have something to do with it.

Any advice? I know more than one of you guys has torn these apart.
 
Clean and inspect everything well and it should go smoothly.
205s are very straight forward to overhaul.
Post some pics.
 
I've done a bunch of 205's and the only real part i've seen worn is the shift fork and the shift rails (people trying to force into a gear).
 
pseudomike said:
What should I look for on those forks?
Click to expand...

The fork ends where they mate with the slider ring should not have any wear in them. They sometimes will get chewed up and have a lip on the mating surface on either side. The last 205 i built a month or so ago had a bad shift fork and my buddy bought one from somewhere in Wa. for something like 25.00 brand new (aftermarket remake but worked perfectly)
 
Anyone have recommendations on where to buy parts? I see a dozen or so places to buy the bearing/seal kit with a google search but very few to buy the small parts, forks, etc.
 
I will get you the name of the place my buddy bought the fork from. Might take me a day or so but i'll get the info for you.
 
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