NP205 Information

NP205: Beefy Transfer Case

Info on the NP 205

The NP205 transfer case is a heavy-duty, gear-driven unit manufactured by New Process Gear in Syracuse, New York. It was introduced in 1969 and used until about 1993. The part-time, manual-shift T-case was found in GM, Ford, Dodge, and International Harvester vehicles, and in some construction/industrial equipment.

This transfer case is considered by most people to be nearly indestructible in most applications. The cast iron housing combined with beefy internals puts this case weight at nearly 140 pounds dry. High-range gearing is 1:1, and the NP205 has a low-range ratio of 1.96:1. It was offered in both driver-side and passenger-side front output versions. There were two input mounting configurations: figure-eight racetrack (as shown in the lead image) and a circular six-bolt pattern. Some versions of the NP205 have also been equipped with a gear-driven PTO output.

Ford used driver-side front outputs and a divorced NP205 in its trucks from about 1972 to 1977, then changed to a six-bolt pattern married NP205 with a 31-spline female input through 1979. Passenger-side-drop divorced cases were used on Dodge trucks in the early 1970s until a married version with the figure-eight mount pattern came along. Inputs used drive sleeves and were male 23-spline in most cases or male 29-spline when used in the diesel trucks behind the five-speed Getrag manual transmission. International Harvester also used a passenger-drop divorced version of the NP205 from about 1969 to 1975. Note that there were some other weird combinations and custom-order variations with the NP205 that are hard to fully describe, so it's a good idea to fully understand what you have in your transfer case before ordering parts.

Rear output shafts on all versions mate to a 32-spline yoke. The 1979 and older versions used a fixed rear-output yoke, while some later versions often used a slip-style yoke at the tail. Front output shafts were typically 10-spline (early) or 30-spline (late) pieces, with the crossover occurring around 1978. Some Ford and Dodge diesel NP205 cases were optioned with a 32-spline front output.

We spoke with Stephen Watson, an NP205 expert from Offroad Design who mentioned a few items to watch for when looking over an NP205 for use or during a rebuild. For starters, the needle bearing stack between the input gear and output shaft can wear grooves in both surfaces and it’s easy to miss inside the cavity of the output shaft. Check the condition of this surface. You'll often find this wear on trucks with substantial road mileage, but they were seldom or never put in low range. High-mileage transfer cases may have the problem of popping out of low range. This could be due to worn needles under the low gears or wear on the shaft and/or low gear. Cases that have been forcibly shifted into gear may show wear issues on the sliding collar teeth and corresponding teeth on the gears themselves. Note also that drive sleeves on male-input NP205 versions can wear and exhibit a sloppy fit. Eventually, the splines can strip out and fail if used under this condition.

Upgrades to the NP205 are readily available today. They include stronger shafts and yokes, shifter enhancements, and lower gearing options. Another big benefit of the NP205 is the fact that it can now be fitted to many more powertrains. There are the OEM adapter components, but aftermarket vendors have added new adapter components to put the transfer case behind an even wider range of transmissions. The NP205 was manufactured as a stout drivetrain component and, with aftermarket support, can handle most anything an off-roader can throw at it.

Break Down

12175       Screw

12176       Retainer, Input bearing

12177       Gasket, Input retainer

12179       Bearing and snap ring, Input

12181       Ring, Retainer Input brg.

12183       Pin, Thrust washer retainer

12184       Spacer, Output gear roller

12185       Gear, Rear low

12186       Bearing, needle

12187       Gasket, rear retainer

12188       Breather

12189       Retainer

12190       Washer, Thrust

12191       Roller 

12192       Ring, retainer

12193       Pin, fork lock

12195       Washer, pilot roller thrust

12196       Clutch, sliding

12197       Gear, input drive

12198       Screw and L/W, front & rear retainer

12199       Gasket, Oil Seal retainer

12200       Oil seal, rear

12201       Yoke, rear out put 1310 series

12202       Washer

12203       Nut

12204       Gear, speedometer drive

12205       Retainer, oil seal

12206       Screw and L/W, rear retainer

12207       Screw, poppet

12208       Gasket

12209       Spring

12210       Ball

12212       Gasket, PTO cover

12213       Cover, PTO

12214       Screw and L/W, PTO cover

12215       Cotter, Link Clevis

12216       Clevis Pin, Shift rail link

12217       Rail, rear shift 12218       Rail, front shift

12219       Oil seal

12220       Link, shift rail

12221       Pin, Interlock

12225       Retainer, front bearing

12226       Filler and drain plug

12227       Transfer case housing

12228       Cone, idler gear bearing

12229       Shim, idler shaft bearing

12230       Cup, idler shaft bearing

12231       Spacer, idler gear bearing

12232       Gear, idler

12233       Shaft, idler gear

12234       Gasket, idler shaft cover

12235       Cover, idler shaft

12236       Screw and L/W, Idler shaft cover

12238       Gear, front wheel high

12239       Shaft, front wheel output

12240       Needle bearing

12241       Retainer

12242       Bearing and snap ring

12243       Roller, pilot

12275       Magnet

12284       Gasket, front retainer

12286       Gasket, rear retainer

12350       Washer, thrust

12351       Shaft, rear output

12352       Ring, pilot roller retaining

12353       Seal, input shaft

12354       Fork, shift

12355       Plug

12357       Oil seal, front

12358       Guard

12359-10  Cv front out put yoke, 1310 series

12359-30  Cv front output yoke, 1330 series

12361       Nut, yoke

R205FD   Master rebld kit, bearing, seals and gaskets

205SPK   Small parts kit