my brother just picked up a 93 4x4 ext cab 5 speed and it has a np205 and its clunking like hell as you shift Ive never torn into a transfer case so Im wondering if you need special tools, what is the cost of parts, is there fine ustments, should we do any upgrades while we are there. Also he has a nv4500 and transfer case out of a 95 12valve Im not sure what t case came in those would it be easier to just put that case in? or would we run into spline problems?

 

nobody has rebuilt a Tcase?

 

I took mine apart a little bit, they're not too hard to do, I don't remember any special tools other than maybe some snap ring pliers etc. I don't even remember any of those but I didn't take it all the way down. The NP205 is a pretty simple unit, brute and simple. I just checked mine out pretty well and didn't see anything wrong so I never completely disassembled it, I mostly just pulled the inspection cover and input adapter housing and a couple other things and checked backlash in the gears and looked inside for any loose or wearing parts or bearings. I have rebuilt other New Process Transfercases before though and all they took was snap ring pliers.

I know the later dodges had a left side drop transfercase while the old ones have a passenger side drop front shaft, so you may want to check that before you think about doing the swap to the later one. I do have an NV4500 in front of my NP205 though and I do love that thing... You do run into a spline count problem on that but you can buy a coupler for the shafts that I think was $170 after the rebate...

The transfercases seem to cost a fortune to buy whole but it seems like the rebuild kits were all under $200