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 Project CJ-7
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Jeep Project CJ-7

An ongoing Budgeted Rebuild/Build up of a Rock Crawling Machine.

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Jeep Central
From Jeep History to Tech Specs and Projects.  This section is all about Jeeps.
Jeep Technical Info
Engine Swaps

Installing 23,000 Volt Offroad Lights

What are
HID Lights?

Onboard Air
Converting a York
AC Compressor
to Pump Air

Warn 9500i Winch Installation

HEI Ignition
Installation & Review

Lockers, Limited Slips &
other Differentials Explained

Jeep Dana 300 TeraLow - 4:1 Gearset for the Dana 300 Transfer Case

Jeep Trans Swap
T-18A Transmission Rebuild & Short Shaft Conversion


NP205 New Process Transfer Case Diagram

The NP205 transfer case is a heavy duty gear driven transfer case in a cast iron case.  The NP205 gear driven transfer case is considered by many to be the king of bulletproof. It was supplied in many GM, Ford, International and Dodge full-size trucks.


Index Number Part Description
1 Yoke Nut
2 Steel Washer
3 Rubber Washer
4 Rear Output Shaft Yoke
5 Output Shaft Oil Seal
6 Rear Oil Seal Retainer
7 Rear Retainer Gasket
8 Rear Bearing Snap Ring
9 Rear Output Shaft Bearing
10 Speedo Gear
11 Rear Bearing Retainer
12 Rear Retainer Gasket
13 Rear Output Shaft Bearing
14 Low Gear Retaining Ring
15 Thrust Washer
16 Thrust Washer
17 Low Gear Roller
18 Roller Spacer
20 Low Gear
21 Low Gear Thrust Washer
22 Low Gear Pin
23 Rear Output Shaft
24 Sliding Clutch
25 Output Shaft Roller
26 Thrust Pilot Washer
27 Pilot Roller Lock Ring
28 Input Shaft With Gear
29 Shift Rail Poppet Screw
30 Ball Poppet Spring
31 Spring Poppet Ball
32 4WD Indicator Switch
33 Poppet Screw Gasket
34 Front Input Shaft Bearing
35 Input Shaft Bearing Snap Ring
36 Input Shaft Snap Ring
37 Oil Seal Adapter
39 Transfer Case Adapter Gasket
40 Transfer Case Adapter
41 Transfer Case Adapter Sleeve
42 Sleeve Retaining Ring
43 Adapter to Transfer Case Gasket
44 Trans To Transfer Case Adapter
45 Idle Gear Shaft Washer
46 Idler Shaft Lock Nut
47 PTO Cover
48 PTO Cover Gasket
49 Clip
50 Magnet
51 Partial Case
52 Idler Shaft End Cover
53 Idler Shaft Cover Gasket
54 Idler Gear Shaft
55 Rear Wheel Shift Fork
56 Shift Rail Interlock Pin
57 Front Wheel Shift Fork
58 Fork To Rail Pin
59 Front Shift Rail
60 Rear Wheel Shift Rail
61 Shift Rail Oil Seal
62 Shift Rail Link
63 Idler Gear Bearing Cone
64 Idler Gear Bearing Cup
65 Idler Gear Bearing Spacer
68 Idler Gear
69 Idler Gear Spacer Shim
70 Front Output Shaft
71 Front Output Sliding Clutch
72 Front Wheel High Gear
73 Front Output Thrust Washer
74 Front Output Shaft Bearing
75 Front Output Bearing Snap Ring
76 Rear Bearing Front Output Shaft
77 Front Output Shaft Bearing Retainer
78 Rear Bearing Retainer, Front Output Gasket
79 Low Gear, Front Output Retainer Ring
80 Front Output Thrust Washer
81 Low Front Output Gear
82 Low Gear Roller
83 Front Output Roller Spacer
85 Front Retainer Gasket
86 Front Bearing Retainer
87 Front Retainer Seal
88 Yoke Flange
89 Rubber Washer
90 Yoke Nut

NP205 Resources:

NP205 Technical Information

NP205 Transfer case Data Sheet

NP203 + NP205 Transfercases
Np203+np205 transfer cases by Gordon Pritchard and bc4x4.com. 

Converting Your NP205 from a single stick to a twin stick
Twin stick conversion for the NP205 is simple and can be done at your home if you manage to get your t-case out of your truck without getting crushed by it.
Building a Bulletproof NP205 Transfer Case
Tips and tricks for the toughest transfer case available, the bulletproof NP205.
How to Fix Up the NP203 Transfer Case
Pertersons 4Wheel & Off-Road details how to rebuild the full-time four-wheel-drive NP203 transfer case.

Transfer Cases Doubler NP203 / NP205 Adaptor
The NorthWest FabWorks Adaptor kit allows you to mate the reduction box portion of a NP203 transfer case to the stout NP205.


NP205 LoMax 3:1 Gears!

NP203 Transfer Case Data Sheet

NP203 based "Doubler” systems
Example of a "Doubler" system: NP203 reduction unit mated to an NP205

New Process 203 Transfer Case Tech





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