NP205 Shift Rails Don't Move Freely

[Chris_In_Idaho]

I recently found a deal too good to pass up on a 1987 V30 sitting in my boss's back 40. Single cab dually 4x4 cab&chassis with a nice aluminum flat bed, 350/SM465/205 4.56:1, pretty cool truck! One of the issues that needs attention is the NP205.

It was in 4 low when I bought it and the link bar between the shift rails was broken in the middle (like maybe someone put a cheater bar on the shifter? I don't know). I thought I should be able to just pull the rails forward with a pair of pliers without too much effort, but they were extremely hard to move. No, it wasn't bound up, it was in neutral with the hubs unlocked and I could rock the driveshafts back and forth by hand. I ended up having to rig a pair of vice grips onto a come along and winch the rails into 2wd hi.

I'd really like to get it shifting correctly, but my np205 knowledge is limited.

Can someone shed some light on what causes the shift rails to move with such difficulty, and how do I fix it?

 

[nvrenuf]

The internal forks on the shift rails are held by roll pins. If someone has beat it hard enough to break the crossbar then I'd guess at least one of the roll pins is jacked and a fork out of position causing other parts to bind. I'm betting you'll need to pull the case and disassemble it.

 

[SpeedlabDan]

You could try pulling the detent caps, springs and balls to see if they are chewed up or even exist anymore. Other than that there's not too much to hang up in there. Short of a failure of one of the shift forks from wear or it being forced you'd have to pull the case apart to inspect that.

 

[sweetk30]

seen water get in the top detent ball cover for the rails and rust them up .

seen long storage rust up the rail were it sticks out .

if the link bar was broken and you didnt move them correctly there is link pins between them to keep you from mixing ranges . its possible you were doing this trying to do 1 at a time .

the np205 is a real easy case to play with .

i have a FULL write up with tons of pics in the advanced articles section . but you need to be a paying member to see that area . https://ck5.com/forums/threads/4l80...05-ord-doubler-3-sticked-its-all-done.253000/

 

[Justin V]

This can be a tough one...

First of all, 205's don't shift that smooth to begin with.

Secondly, there are detents in the rails that are designed to keep them from shifting certain ways from the factory.

Because you said the crossbar was broken/cut/disconnected I have to assume that you likely were pulling on the wrong rail at the wrong time to make everything play nice together...

But there could simply be rust or corrosion stopping the free movement. Maybe there is/was water in the case. How long did it sit? I'd check out a youtube video or five and pull the t-case and disassemble it. They aren't that bad, and you'll know for sure what is up...

 

[Chris_In_Idaho]

Thanks for the info. The truck is my daily driver right now so unfortunately tearing the transfer case apart isn't really possible. I've been watching Craigslist and there have been five or six figure 8 np205s for sale in the last couple of weeks but not a single 6/round np205. Next time I have a couple days off I'll try pulling those detent balls out to see what I can see.

 

[sweetk30]

a round 6 bolt will be hard to find as 85-91 only and worth big bucks.