QU50480 Basic NP205 Small Parts Kit is an affordable Kit for all NP205 transfer cases. QU50480 includes 2 Thin Steel Low Gear Thrust Washers with Bent-over tabs, 1 Thick Cast Iron Low Gear Thrust Washer, Low Gear Snap Rings, 0.085" Thick Input Shaft Snap Ring for 10, 23, 27 spline inputs, 143 Needle Bearings, Pilot Bearing Thrust Plate, Detent Springs, Detent balls, 2 Slotted Steel Shift Fork Pins, and 2 Low Gear Bearing Spacers. Contains a combination USA made and imported aftermarket parts. Important: If you have a 1982-1987 GM synchronized NP205 see Tech Note 3!
Also available: QK2060 and QK2061 Premium Complete NP205 Small Parts Kits
QU50480 is a basic NP205 Small Parts Kit suppled by an aftermarket company. It includes the minimum amount of parts needed for a low dollar rebuild. QU50480 is a good choice for cases that are in pretty good shape, but it does not include ALL the small parts! If you want or need a COMPLETE Small Parts Kit, see our QK2060 and QK2061 Kits.
Need Tech Help on rebuilding your NP205? Get my TM2000 New Process NP205 Transfer Case Service Manual. A Complete NP205 shop Manual with over 375 color photographs is your indispensable NP205 resource for Repair Procedures and Parts Identification. Complete coverage of Disassembly, Inspection, and Reassembly Procedures. Also, Shop Notes, Tool Recommendations, Complete Parts Guide, and full color Exploded Views, including Right Drop and Left Drop Models, plus GM Specific Parts. Covers New Process NP205 Transfer Cases found in Chevrolet, Dodge, Ford, GMC, and International Harvester (IHC) 4x4 vehicles from 1969-1993.
Or my TM2002 for the Exploded Views and Parts Guide only. Fully Illustrated with dozens of crisp color photographs for EASY Parts Identification! This Manual includes 10 page Parts Identification Guide with full color Exploded Views.
From 1982 to perhaps as late a 1987, General Motors offered a synchronized NP205 Transfer Case on 1 ton trucks with auto locking hubs. These synchronized cases use some special front output small parts that are NOT included in our Small Parts Kits. The easiest way to tell if you have a synchronized or non-synchronized NP205 is to look at the large, 8 bolt round front output, rear cover on the backside of the main case. With non-synchro cases, there is a through hole in the middle of the aluminum cover in which is pressed the front output, rear support bearing. The steel, 2-1/8" diameter, closed end bearing is easy to see in the center of the cover. Synchronized covers are solid and the 1-7/8" OD open end bearing is not visible to the outside, but you will be able to see the raised, solid area of the casting were the bearing is installed.
You will have to reuse these parts which are no longer available:
QU30080 Front Output Low Gear Bushing
QU30076 Front Output Low Gear Thrust Washer
Input Shaft End-Play on direct mount models and rear output shaft end-play on 1980-1991 GM units with slip yokes is minimized by the use of selective fit snap rings. You want to use the thickest available ring that will fit in the shaft groove with the ball bearing installed. There is no published specification for NP205 input or output shaft end-play. Typically, there will be a fair amount of noticeable end-play due to movement of the ball bearings in the case bores.
1969-1993 New Process NP205 Transfer Cases