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New Process NP205 Transfer Case Common Parts

This legacy page is for reference only, please go to our new NP205 Parts Page for a complete listing of all the NP205 parts, tools, and manuals we carry!

New Process Gear of Syracuse, New York manufactured the rugged and reliable NP205 gear drive transfer case for 1969 to 1993 model year full size 4x4's.  It was offered with both remote mount and direct mount configurations.  Right Drop 205 cases were used by Dodge from 1969 to 1993 and by GM from 1969 to 1991. Ford used left drop cases from 1973 through 1979.  International used right drop 205 remote mount transfer cases from about 1969 until light truck production ceased in the mid 1970's.  A number of 205 parts also fit NP200 cases in 1967-1969 Jeep 1¼ ton M715, M725, M726 series military trucks and the NP200 and 201 cases found in older Dodge and International trucks.

The NP205 is a cast iron, gear drive transfer case with a 1:1 high range and a 1.96:1 low range.  Considered by many to be the strongest transfer case ever factory installed in one ton and smaller 4x4's.  The basic design of the 205 remained unchanged throughout its production history with the exception of synchronized front output shaft briefly used by GM in the early 1980's.  The synchronized version was intended to provide shift-on-the-fly 4x4 capability with automatic locking hubs.  Unfortunately, it didn't really work out as intended, and GM canceled the production contract almost immediately, but they were obligated to take enough units to pay for New Process's tooling costs.  Most synchronized 205's are in the 1982 model year GM 1 tons, however, GM still had enough transfer cases on hand to apparently offer it as an option on 1 ton trucks for several more years. The last production vehicle to use the NP205 was the 1993 Dodge pickup equipped with the Cummins Diesel engine.

We have the most complete inventory of new, genuine, American Made New Process Gear NP205 transfer case parts in the world.  Genuine New Process gears and shafts feature outstanding fit, finish, and durability so critical to high performance NP205 applications.  New for 2010, we now also stock, quality, low cost, aftermarket replacement gears and shafts for your NP205 Transfer Case.  These aftermarket parts will give great service for most NP205 applications, but if you are running a  Cummins Diesel or  souped-up gas engine in front of your 205, we strongly recommend you stick with genuine New Process gears and shafts for maximum performance and life.

Page Link Bar

QU50084 Rear Output Shaft

NP205 Low Gear

Dodge
 

Front Output/Remote Mount Input Bearing Retainer

QU50188
Direct Mount Input Flange

(VERY Limited Supply on these genuine NPG flanges.  When they're gone, they're gone!)

QU10686 Front Output and Remote Mount Input Bearing Retainer with Seal	Please Refer to NP205 Parts Page
QU50188 Ford and GM Round, 4 bolt Direct Mount Input Bearing Retainer	Please Refer to NP205 Parts Page

Dan the Gear Man® Tech Tip:  Unless you have a good impact type seal puller, remove the retainer from the transfer case and drive out the seal when replacing the output seals on NP205 transfer cases. Attempting to replace the seals in the vehicle, usually results in a badly gouged, screwed up, or broken retainer. 

QU10528 89-93 Dodge
29 Spline Coupler Sleeve

Rear Output Yoke Kit

Front Output CV Flanges are shown on our Dodge Transfer Case Page



 

Output Yoke Kits make it easy to replace a damaged yoke or to retrofit your transfer case for a heavier u-joint.  Kits include yoke, rear seal, spline seal, shaft washer, shaft nut, u-joint strap kit, and threadlocker.  Yokes will fit 32 spline front/rear output shafts and remote mount input shafts.  Made in U.S.A.

QK2015 Rear Yoke Kit for 1350 series U-Joint replaces the original equipment yoke on ¾ and 1 Ton GM trucks with fixed output yokes and some IHC trucks.  A popular upgrade for rock crawlers	Please Refer to NP205 Parts Page
QK2016 Rear Yoke Kit for 1410 series U-Joint replaces the original equipment yoke on 1989-1993 Dodge trucks with the Cummins Diesel Engine. A popular upgrade for sled pullers and hard-core Offroaders.	Please Refer to NP205 Parts Page
QK2015F Front Yoke Kit for 1350 series U-Joint replaces the original equipment input yoke and front output yoke for high performance applications.  Yoke has steel deflector/slinger to protect the seal from damage.  A popular upgrade for rock crawlers.  Very Limited Supply!	Please Refer to NP205 Parts Page
QK2033 NP205 Yoke Kit for 1310 series U-Joint	Please Refer to NP205 Parts Page

Genuine New Process Shift Forks  will replace either shift fork in your 205 transfer case.  Note:  Will not replace the special fork used in 1982-1986 GM synchronized NP205 cases.  Made in U.S.A. Very Limited Supply

Genuine New Process Clutch Collar Rings will replace either clutch collar in your NP205 transfer case.  The leading edge of the teeth on the original collars are often worn from forcing the transfer case into gear.  Note: Will not replace the special collar found in 1982-1984 GM synchronized NP205 cases.  Made in U.S.A. (Very Limited Supply)

QU10661 NP205 Clutch Collar	Please Refer to NP205 Parts Page

Except for our Torque King® Gasket Kits, virtually all gasket sets available for the NP205 transfer case are supplied by aftermarket vendors.  Although they are inexpensive, these aftermarket kits not made to factory specified dimensions so fit and part clearance problems are often encountered.  Another problem with most  aftermarket gaskets is quality of the material they are cut from.  The aftermarket gaskets we have tried either tear or extrude out under compression.   Since we started rebuilding NP205 transfer cases in the 1970's, we have found the only gaskets worth installing are genuine original equipment gaskets sourced from New Process.  All the gaskets found in our Torque King® Gasket Sets are genuine original equipment components as are our individual gaskets. Our Gasket, bearing, and overhaul kits will be shown on our vehicle specific transfer case pages:

Chevy/GMC Transfer Case

Dodge Transfer Case

Ford Transfer Case

QU10519 Adapter Gasket

6 bolt round Transfer Case Adapter Gasket fits most Dodge, Ford, and Jeep applications with the round, 6 bolt mounting flange with or without dowel alignment pin.  Also fits many GM full size applications and U.S. Gear 2 speed auxiliary transmissions. Genuine original equipment gasket. Included in Torque King™, vehicle specific gasket, rebuild, and overhaul NP205 kits. Made in U.S.A.
 

QU10519 6 bolt Adapter Gasket

Please Refer to NP205 Parts Page

6 bolt round Transfer Case Adapter Gasket with Cutout fits between the cast iron transmission to transfer case adapter and the front of the NP205 Transfer Case used on 1985-1991 GM  square body style 1 Ton trucks with the round bolt pattern front adapter. Genuine original equipment gasket. Included in Torque King™, vehicle specific gasket, rebuild, and overhaul NP205 kits. Made in U.S.A.
 

QU30036 Adapter Gasket

Please Refer to NP205 Parts Page

QU10529 Adapter Gasket

Transfer Case to Adapter 8 Bolt Gaskets fit direct bolt NP205 transfer cases in GM and Dodge applications with the 8 bolt, hourglass pattern from 1969-1993. Genuine original equipment gaskets made to precise dimensions for proper clearances.  Included in vehicle specific Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A.

Standard Bore Adapter Gasket fits all direct mount 205 transfer cases in  GM and Dodge vehicles EXCEPT 1989-1993 Dodge Cummins Diesel trucks with 5 speed transmissions and Chevy or GMC trucks with the Turbo 400 or 700R4 automatic transmissions and late SM465 4 speeds with a 32 spline output. Limited Supply!

QU10516 205 Std Bore 8 Bolt Adapter Gasket

Please Refer to NP205 Parts Page

Large Bore Adapter Gasket fits1989-1993 Dodge Cummins Diesel trucks with 5 speed transmissions and Chevy or GMC trucks with the 32 Spline Turbo 400 or 700R4 automatic transmissions up to 1985.  Gasket is sized to clear the oversize input bearing found on these applications.  Limited Supply!

4 Bolt Retainer Gasket

4 Bolt Bearing Retainer Gasket fits all NP200, 201, NP205 and NP203 front output bearing retainers, and all NP200, NP201, and NP205 remote mount input bearing retainers. Genuine original equipment gasket made to precise dimensions for proper clearances. Included in all our Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A
 

QU10514 4 Bolt Retainer Gasket

Please Refer to NP205 Parts Page

Rear Retainer Gasket

Rear Bearing Retainer 5 Bolt Gasket for all NP200, NP201,  and NP205 transfer cases.  Has cutout for oil feed passage found on many of these transfer cases. Genuine original equipment gasket made to precise dimensions for proper clearances. Included in all our Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A.
 

QU10503 5 Bolt Retainer Gasket

Please Refer to NP205 Parts Page

Rear Housing Gasket

8 Bolt Rear Housing Gasket for all NP200, NP201, and NP205 transfer cases is used between the main housing and rear housing and/or bearing supports.  (2 required per transfer case, but sold individually) Genuine original equipment gasket made to precise dimensions for proper clearances. 2 Included in all our Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A. Very Limited Supply.

QU10604 Rear Housing Gasket

Please Refer to NP205 Parts Page

Idler Cover Gasket

Idler Shaft Cover Gasket for all NP200, NP201, and NP205 transfer cases Genuine original equipment gasket. Included in all our Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A. (Very Limited Supply!)

Poppet Plug Gasket fits all NP200, 201, and 205 Transfer Cases.  Used under each shift poppet plug or shift indicator switch. Genuine original equipment gasket. Precision cut from the correct thickness material to provide accurate poppet spring tension. Requires two per case, but sold individually. 2 Included in all our Torque King™ gasket, rebuild, and overhaul NP205 kits. Made in U.S.A. (Very Limited Supply!)
 

QU10680 Poppet Plug Gasket

Please Refer to NP205 Parts Page

QU10517 Double Lip Seal

Input Seal for GM models with the Turbo 400 automatic transmission, most Ford direct mount cases and Dodge 89-93 Diesel 5 SPEED trucks is a double lip, double spring seal. A quality original equipment seal designed to retain fluids from either direction.   Made in U.S.A. or Mexico

Input Seal for REMOTE Mount transfer cases: See Rear Output Seals

Input Seal for All Other GM applications: CALL us at 406-446-2427

Double Seal Kit

QU10510 Front Output Seal

Front Seal for GM 1973-1979 NP203 and 1969-1991 NP205 transfer cases. Two types available.  Choose from an original equipment, double lip, double spring seal or and advanced design, hydrodynamic lip for leak free performance.  Seal is flanged to seat against retainer and has recess for yoke-slinger clearance.  Made in U.S.A. or Mexico

QU80044 Original Equipment type Double Lip, Double Spring Seal for GM applications.	Please Refer to NP205 Parts Page
QU50124 Hydrodynamic GM Front Output Seal	Please Refer to NP205 Parts Page

Front Output Seal  for Dodge 1981-1993 and all other models with 1-7/8" yoke diameter.   Double lip, double spring seal is genuine original equipment replacement.  Made in U.S.A.

Most Ford and all Remote mount applications:  Same as rear output seal.

Shift Rail Seal Set

Spline Seal

Spline Seal for Output Shafts. Three styles available. QU10513 is approx. .182" thick with 32 splines and is the best fit for 205 early front output shafts using standard yokes, rear output shafts and remote mount input shafts  QU50125 is approx. .130" thick with 32 splines and is the best fit for most 32 spline front output shafts with CV flanges or yokes and a one piece nut/washer.  QU30033 fits GM 30 spline front output shafts Note:  These seals do not work with GM 10  front output shafts.  Made in U.S.A.

QU10513 Thick 32 Spline Seal	Please Refer to NP205 Parts Page
QU50125 Thin 32 Spline Seal	Please Refer to NP205 Parts Page
QU30033 30 Spline Seal for GM front output shaft	Please Refer to NP205 Parts Page

High Gear Thrust Washer

NP205 Small Parts Kit
(Case Plugs not shown)

For pricing and to order, go to our 4x4 Tools Page